Our company specializes in developing and customizing medical products using silicone and various foaming techniques. One of our notable projects involved creating a custom IV injection training product for Client A. Initially focused on developing injection-related products, we swiftly adapted to Client A's specific customization needs. This case study outlines the process, challenges, and solutions we implemented to deliver a high-quality product that met the client's requirements.
Project Overview
Client A approached us with a unique idea for an IV injection training product. She provided a general concept, and we quickly sketched a preliminary design for her review. The initial steps included confirming the vascular thickness, direction, and skin thickness to ensure the product would meet realistic training scenarios.
Development Process
1. Conceptualization and Design
- Initial Discussion and Sketching: Client A shared her vision for the product, emphasizing the need for durability and realistic texture. Our team created a quick sketch, which was approved by the client.
- Material Selection: We chose silicone for its durability and flexibility, and explored foaming techniques to achieve the desired texture and firmness.
2. Prototype Creation
- Vascular and Skin Thickness Confirmation: We validated the necessary specifications for the vascular and skin components, ensuring they matched real-life anatomical features.
- Handmade Prototype: After finalizing the design, we produced a handmade prototype for Client A's evaluation. This step was crucial for refining the product before mass production.
3. Mass Production Preparation
- Mold Making: We proceeded with mold creation, a critical phase in transitioning from prototype to mass production.
- Sample Approval: The handmade prototype was refined based on Client A’s feedback, and the final sample was approved for mass production.
Challenges and Solutions
Challenge 1: Understanding and Realizing Customer Needs
- Issue: The initial product made with sponge material was too soft, and the skin layer was too thin, making it prone to tearing during training sessions.
- Solution: Utilizing the client's product image and extensive research on various online platforms, we sourced a sample of a similar product. We then proposed using a firmer PU foam instead of sponge and increasing the silicone skin thickness to 2mm for enhanced durability. This adjustment ensured the product could withstand rigorous use by students.
Challenge 2: Quality Control in Silicone Vulcanization
- Issue: The silicone skin experienced some losses during the production process, increasing production costs.
- Solution: We implemented stringent quality control measures throughout the production process. Regular inspections and adjustments were made to minimize material wastage and ensure consistent quality in the final product.
Challenge 3: Mold Maintenance
- Issue: Over time, molds used for large-scale production required maintenance to maintain product quality.
- Solution: We established a routine maintenance schedule with a trusted mold manufacturing partner. This partnership ensured that molds were regularly serviced and repaired, preventing production delays and maintaining high-quality output.
Conclusion
The successful completion of this project demonstrated our ability to understand and fulfill client needs, leverage our expertise in silicone and foaming techniques, and manage production challenges effectively. Our collaborative approach and commitment to quality control enabled us to deliver a durable, realistic IV injection training product that exceeded Client A's expectations. By using cost-effective materials and innovative solutions, we helped our client save costs while achieving their product development goals.
