Projects

Ergonomic Keyboard

Our client had an idea for a better keyboard design.  He reviewed all ergonomic keyboard and mouse options that were on the market and came up with a series of small changes to keyboard design that make huge improvements to ergonomics.  The client came to Boost Design to get assistance with bringing the product to market, which involved the following activities:

• Development of a development plan suitable for the product and client
• Development of proof-of-concept electronics and firmware
• Industrial design and rapid prototyping of a proof-of-concept keyboard assembly, suitable for initial testing
• Refinement of designs into a first keyboard prototype, suitable for user testing, which underwent several rounds of refinement in order to perfect ergonomics for users
• Work on electronic and keyboard design for manufacture (DFM) with chosen suppliers
• Organised production tooling
• Developed high-quality product concept images
• Provided guidance with IP protection, certification testing, and product marketing
• Provided other general startup guidance and support

The keyboard has won the international Red Dot Design Award for Excellence in Design and a Gold Australian Good Design Award. The Australian Good Design Awards Jury say:

“This is a design of true integrity. A highly innovative ergo keyboard, packed with many ergonomic features – including a patented sliding palm-rest solution. Positive online reviews suggest this is already well received well in the marketplace.” 

The keyboard has also been listed on the cnet news website: “Best Keyboard for 2021“.

It is available for purchase from the company’s website: https://www.zergotech.com/

SureVis Thermal Camera

Thermal imaging is a non-invasive and convenient method for facilitating the rapid screening of human skin temperature. It is well suited to picking up common symptoms of illness such as COVID-19, and in turn can be used to help keep public spaces and workplaces safer.  In response to the pandemic, Medlauncher engaged Boost Design to research and develop a new thermal imaging camera suitable for use in the post-COVID-19 recovery.  As part of this project, Boost Design completed the following activities:

• Conducted research into available technologies and limitations
• Invented a new approach to produce a high-accuracy thermal imaging camera at a fraction of the cost of comparable offerings
• Developed a benchtop proof-of-concept of the technology, including electronics, firmware, software, and industrial design, proving feasibility of the low-cost technology
• Developed sales and marketing assets allowing the Client to test the market prior to committing to further development
• Conducted patentability searches and freedom to operate searches, and applied for a provisional patent on the technology
• Designed a prototype of the device suitable for performance testing
• Developed test methodologies and equipment to verify camera performance and accuracy
• Designed and developed all industrial design, electronics, firmware, and software for the production device
• Designed customisable mounting solutions, including desk mounts, floor standing mounts, and wall mounting systems
• Developed an upgraded software package, allowing WiFi connection of the camera to a local network, and a highly-configurable automated alert system that sends notification emails when high temperatures are detected
• Manufactured short-run production devices on behalf of the client

The SureVis Thermal Camera has won an Australian Good Design Award; the Jury commented:

“A great example of a product response to the COVID-19 pandemic. SureVis provides a well designed solution at a cost that is achievable to SMEs. The user experience of the device is simple and has been thoughtfully designed. Materials, design selection. workflow and aesthetics are of high quality.”

IoT Farm Management System

Crop farmers need to carefully manage their water supplies to ensure efficient and eco-friendly operations.  The aim of this project was to develop a system with the ability to monitor and control a farm irrigation system from anywhere, including from the office, as well as out in the field, saving the farmer hours of commuting and manual water management work each day.  Boost Design was engaged to develop a system and conducted the following activities:

• Work closely with the client to determine the functionality requirements of the product
• Research and determine the best wireless communications system for their needs (LoRaWAN)
• Research a range of internet dashboard systems, providing a platform for rapid dashboard and control system development, along with the flexibility to meet future needs
• Develop a proof-of-concept of the electronics and firmware, to confirm correct operation prior to designs being committed to printed circuit boards
• Design custom electronics to operate a wide range of inputs and outputs, providing flexibility to meet the needs of widely-varying configurations and different farm sites
• Develop a prototype system dashboard with the flexibility to be configured to the needs of each individual installation
• Develop a system for onsite manual override control, as well as fail-safes for the unlikely event of network failures, giving farmers peace of mind that they will always be in control
• Manufacture prototypes suitable for field usage and testing
• Complete industrial design of an IP-rated enclosure suitable for outdoor usage
• Arrange certification testing
• Arrange production tooling

This device is available for purchase from the Farm Management System website.

3D BioPrinter

Inventia Life Science (www.inventia.life) has developed a revolutionary high-throughput 3D bioprinting technology for use in biomedical research and regenerative medicine.  This system utilises additive deposition of natural and synthetic bio-inks, as well as living cells, to create 3D structures for use in a range of laboratory and research applications.  Boost Design was engaged and performed the following activities:

• Conducted a preliminary review on the device’s suitability to achieve regulatory compliance, including EMC and Electrical Safety
• Designed system schematics based on Inventia’s pre-existing proof-of-concept electronics
• Redesigned numerous electronic systems into a single integrated electronic circuit board, reducing assembly complexity, reducing cabling requirements, improving noise immunity, and maximising system reliability
• Integrated motor drive systems to minimise component count and costs
• Integrated provisions for additional sensing systems to aid with system performance monitoring and workflow
• Worked closely with the Inventia team to maximise compatibility between the existing firmware codebase and the newly designed hardware
• Arranged regulatory certification testing and associated documentation (CE, FCC, RCM marking etc) to gain approval for sale in major markets
• Produced proof-of-concept, prototypes, and production designs for electronics
• Organised production of electronics for launch products

A video with more information about the product can be found here: Inventia Rastrum 3D BioPrinter

Read about one of Inventia’s customers here: 3D Bio-Printer Installed at Peter Mac Cancer Centre to Accelerate Research

The Rastrum Printer has also gone on to win the Australian Good Design Award for Design of the Year, beating a number of other outstanding entrants to receive the award’s highest prize.

Stainless Steel Straw Dishwasher Rack

Suckitup (SIU) initially came to Boost Design to discuss a concept for how to encourage the use of reusable stainless steel straws in the food services industry. Starting with a much more complex idea, Boost worked with SIU to simplify the project to address one of the core challenges facing the adoption of reusable stainless steel straws; easy and effective cleaning.

On this project Boost Design completed the following activities:

• Worked with SIU to develop a product solution that would ultimately encourage the uptake of reusable straws in the commercial environment
• Developed a range of design concepts to explore potential product configurations suitable for maximising straw capacity and cleaning, whilst also being compatible with commercial dishwashing systems
• Generated a series of high-quality product renderings that illustrated a range of aesthetic design options which SIU were able to use to confirm market interest with their potential customers and key stakeholders
• Investigated a range of suitable recycled materials for use in the final product. The racks are made from 50% recycled, injection moulded polypropylene
• Developed a proof-of-concept prototype such that ease-of-use and cleaning performance could be assessed within a commercial environment
• Identified suitable vendors for large scale manufacture, and undertook DFM (Design for Manufacture) with nominated suppliers
• Arranged tooling and production of final product

The product was awarded a Gold Good Design Award; the Jury commented:

“Any reduction in the number of disposable drinking straws is a positive thing, Suckitup go further to provide an all in one solution. This is a well-resolved, integrated and aesthetic solution to the issue of cleaning metal reusable straws. It’s a really innovative product that addresses a huge need – by making the straws easy to clean, uptake will be increased. Consideration of the user experience is evident in the design, as is engagement with the people that will use the product. The approach to packaging the design as a complete unit (straws + cleaning rack) is really clever and removes barriers to purchase. A really well executed design.”

You can find out more about SuckItUp on their website https://suckitupstraws.com.au/.

See a video of the product in action here: https://www.youtube.com/watch?v=KRpnQm2nkW8

Wearable Medical Device

This project was conceived by Professor Barry Marshall, a Nobel Prize winner based at the University of Western Australia.  Designed as a diagnostic and screening test, this system listens to gut noises and utilises proprietary algorithms to determine the likelihood of the patient having one of a number of types of gut disorders (including Irritable Bowel Syndrome).  Aptly named “The Noisy Guts Project”, this technology aims to make gut disorder diagnosis non-invasive and much more convenient than current methods. Boost Design was engaged to work on the project and conducted the following activities:

• Developed a hardware development plan to efficiently achieve project goals within the constraints of available funds
• Worked with the client to determine appropriate gut sensors and consulted on sensor acoustic design
• Consulted on medical device requirements relating to product development (ISO13485 and IEC60601 electrical safety)
• Designed all of the electronics and firmware for the product, including miniaturised sensor electronics, a high-speed data recording and storage system, rechargeable battery & battery management system, and user interface
• Developed proof-of-concept electronics for testing the functionality of the hardware and firmware, and identified a range of complex hardware performance issues that were then risk-managed and resolved as part of the development process
• Developed electronics schematics and printed circuit board designs
• Manufactured, assembled and tested a number of systems, and supplied these to the client for usage on patients
• Provided engineering and technical support during the clinical trial

This product is currently undergoing clinical testing, prior to undergoing development into a commercial product.

Further information relating to the technology can be seen here: https://www.youtube.com/watch?v=PFgVtcAb8U4

Cryptocurrency Miner

Mining is a process where cryptocurrency coins are generated utilising specialised processing hardware and software. Our client developed a prototype system designed to mine Skycoin cryptocurrency which combined a number of readily available existing technologies.  While the prototype worked effectively, it was expensive to produce and time-consuming to assemble.  Boost Design was engaged to perform a DFM (design for manufacture) review and product redesign, which included the following tasks:

• Review the electro-mechanical assembly and identify options for reducing the number of parts
• Redesign the electronics to remove a number of expensive third-party components and integrate them into a single motherboard design, incorporating high-speed ethernet
• Redesign the enclosure to reduce size, cost, simplify assembly, and improve aesthetics
• Consolidate the device’s power management to a single and much lower-cost power supply
• Remove nearly all cabling from the design, simplifying the supply chain, reducing costs, and reducing potential failure points
• Evaluate the assembly process and redesign the system to significantly reduce complexity and labour requirements
• Implement design changes to significantly reduce compliance certification costs & risks, both for EMC and electrical safety tests
• Generate high-quality product digital images for marketing purposes
• Arrange for pre-production devices to be manufactured in preparation for certification testing and product launch

This product is available for sale from the SkyBox Pro website.

Laboratory Machine

In this project Boost Design was assigned to develop the electronics and firmware for a complex high-speed laboratory system to replace an ageing product.  This system needed to be faster than their existing technology, more automated to remove manual tasks from operators, as well as more versatile to open greater market and revenue opportunities.  Additionally, commercial pressures dictated a very short development timeline.  Boost Design conducted the following activities:

• Rapid development of a proof-of-concept device
• Invention of an automated high accuracy (better than +/-0.025mm) animal measurement system, including research, development, and prototype evaluation
• Testing and implementation of a range of motor options to achieve optimal combinations given product and project constraints
• Modelling to predict system performance, and algorithm design to minimise process time
• Design of the embedded microcontroller, stepper motor controller, and BLDC motor controller schematics and PCBs
• Design of other electronic systems, including a basic user interface with tri-colour LEDs
• The solving of complex mathematical problems leading to novel algorithm development to further the device’s automation capabilities
• Development of sophisticated motor and process control firmware
• Production and testing of electronics and firmware

Medical Device Disinfector

This device is a Class IIb medical device designed for the disinfection of ultrasound probes. This product is the market leader with 1000s in operation in hospitals and clinics around the world, with the company achieving a market capitalisation of approximately $1bn on the ASX based on the sales of this product.  Boost Design’s founder was previously the head of research, design and development for the company where he either led or was involved in the following activities:

• Development of the product from proof-of-concept to successful global product
• Technology research and innovation program leadership
• Product engineering, including mechanical, electronics, software and firmware, physics and material sciences
• Customer needs assessments and next-generation product requirements development
• Commercialisation strategy input, including sales and marketing programs, tradeshows etc.
• Service and support strategy development
• Ongoing engineering support of the product in the field and in production
• IP protection (five patents and one design registration)
• Development of all design and validation documentation,audited by TGA and CE notified bodies
• Compliance with ISO13485 medical device quality system and other appropriate standards
• Product Certification to achieve regulatory approval for sale in major markets globally

A video describing the technology and operation of the product is shown below:

Touchscreen Bluetooth Controller

As part of a Client’s new product innovation plan, the client aimed to develop a wireless touchscreen controller for their growing range of laboratory products.  Boost Design was engaged and performed the following activities:

• Research and present options for the Bluetooth Controller processor mainboards that would be powerful enough to run the Client’s Windows-based controller software
• Research and present options for touchscreen displays of the requisite resolution, quality and compatibility with the mainboard and Client software
• Source some of the hardware options, configure them, and perform basic testing
• Scope multiple electronics options that would meet the product’s connectivity requirements
• Design schematics and PCBs for a custom interface board to integrate with the system
• Manufacture and test the electronics
• Design and develop a Bluetooth API to operate on the Windows platform, allowing bi-directional communications between the controller and wireless Bluetooth laboratory devices
• Design and develop Bluetooth communications code for a related laboratory product, allowing remote control from the Bluetooth Controller.
• Supporting the client in identifying and resolving production faults

Motor Controller

An inventor had been working on developing a remote-controlled motor drive system for a new product to be used in the agricultural industry, and they had come across challenges in getting their prototype to work effectively. Boost Design was engaged to assist and performed the following activities:

• Worked with the client to create a product development plan suited to their needs
• Reviewed the provided mechanical designs and developed proof of concept electronics to test the provided motor drive system
• Identified performance issues with the supplied motors, hence researched and respecified the drive system to meet load and speed requirements
• Developed proof-of-concept electronics to bench test drive motors and confirmed performance met expectations
• Developed a Bluetooth control system for wireless remote control of the motor drives
• Developed a Bluetooth handheld control unit, with integrated battery power and custom electronics
• Iterated on the handheld controller design to improve ergonomics and maximise ease of use
• Developed custom electronic schematics and PCBs suitable for use in the prototype
• Manufactured a working prototype control unit suitable for field use

This product is currently undergoing field trials.

Radiology Medical Device

Breathe Well is a Class I device designed to assist cancer radiation patients better control their breathing in order to achieve improved treatment. Key activities undertaken by Boost Design include:

• Review of regulatory strategy and existing TGA/FDA documentation prior to submission
• Translation of product features into testable requirements
• Development of basic verification and validation test procedures
• Development of single-fault risk assessments and mitigations
• Manufacturing strategy planning
• Compliance and certification test support
• Engineering support
• General start-up guidance and advice

A patient information video for the product can be viewed below:

Elite Sports Performance Sensor System

High-performance sensor electronics were designed from scratch for the purposes of detecting and classifying the human motion of elite athletes.  This product was to be used as a research platform for algorithm development and testing.  Project activities included:

• Determination of needs, and development of project scope and product requirements
• Development of experimental techniques for quantitative analysis of sensor performance and comparisons
• Systems and architectural design of electronics, software, and hardware
• Electronics, firmware, and embedded software design
• Integration of electronics into sports garments
• Battery system design and power budget
• Wireless streaming of data to a computer for in-depth processing
• Data synchronisation with video
• Providing on-going support and improvements
• Provided on-going manufacture of sensor systems
• Development of calibration, sensor verification and manufacturing tests

Linesaver Medical Device

This Class I medical device is designed to externally protect cannulas, the thin tubes inserted into a vein that administer fluids and medication to hospitalised patients.  The Linesaver device is strapped to the arm or hand, and protects the patient from injury if the cannula is accidentally bumped or the IV line pulled. Activities included:

• Matching product requirements with design and technology feasibility
• Design reviews and design management consultation
• Medical Device quality and regulatory consultation, including regulatory strategy development, and creation of appropriate documentation and company processes to support device registration and approval for sale
• General technology startup company commercialisation advice and support

IoT Consumable Tracking System

As part of a larger project, Boost Design was engaged to develop a system to track the use of re-usable consumables in a laboratory device.  The system required miniaturised electronics to be attached to each consumable, suitable for high volume production at low price.  The system needed the capability for each consumable to be individually identified, to have usage tracked, to support multiple types of consumables, and to allow for partially-used consumables to be re-installed into the device and function appropriately.  Parts of the consumables required electron beam sterilisation, hence system and process design had to allow for this without damaging the tracking device.   The designed also needed to consider the integration with the Clients pre-existing IoT cloud infrastructure to allow for data to be centrally tracked.  Boost Design conducted the following activities:

• Collation of requirements to meet design goals
• Research and selection of key technologies and components
• Conception of the sterilisation processes for the completed consumable system to ensure electronics would not be damaged in production
• Development of a proof-of-concept
• Schematic and PCB design of the electronics (consumables and device reader)
• Manufacture of electronics
• Development of microcontroller driver firmware to facilitate communications between the laboratory device and the consumable tracking electronics

Laryngoscope Research & Development

Airway Medical Innovations (https://airwaymedicalinnovations.com) is developing a novel Laryngoscope device incorporating new endotracheal intubation technology that is safer, quicker, and easier to deploy.  As part of their product development, Airway Medical Innovations engaged Boost Design to complete the following activities:

• Researching competing laryngoscope products, and recommending a range of design requirements for key product features
• Determining methodologies for comparing Airway Medical Innovation’s prototype with other devices already released to market, and performing associated testing
• Researching options for various improvements to the prototype, and developing basic proof-of-concept electronics such that performance criteria were exceeded

Airway Medical Innovation’s Laryngoscope is currently undergoing further development.

Industrial Microwave System

The Client had developed a prototype industrial microwave heating system, and required engineering assistance to be able to progress technology development. Boost Design was engaged for a short research project and performed the following activities:

• Review of Client needs and objectives
• Background research into microwave technology
• Review of existing prototype, and its limitations
• Developed actionable improvements for the Client to implement in their next round of development

Sports Wearable

In this project the Client wanted to integrate smart electronic sensing into their own (non-electronic) sports products.  Boost Design was engaged to research the viability of the project, technology, size and power requirements, analyse competing products, and develop the product for manufacturing.  Boost Design performed the following tasks:

• Located and reviewed white papers and peer-reviewed articles on related sports topics to understand requirements for hardware and algorithms in relation to human biomechanics
• Researched competitive products to find a market niche, quantified the market opportunity, and identified an appropriate commercialisation strategy
• Completed a feasibility analysis on the electronics, developing a strategy to miniaturise the product whilst maintaining adequate battery life
• Selected core product electronic components and developed a digital mock-up circuit board to establish size requirements
• Recommended IP and patenting opportunities to pursue

This sports wearable product is currently in development.

Retro Recording Equipment

This project was to research, design and build a prototype of a unique audio recording device based on proven circuitry used in classic studio equipment popularised in the 1970s. This device comprises a preamplifer circuit combined with a FET limiter circuit. Activities included:

• Research classic studio audio equipment and usage
• Define product requirements and specification, and design
• Source components (including vintage-reproduction components)
• Prototype and test

Technology-to-Market Strategy

Our client had an existing technology but were unsure how to best bring it to market. Boost Design conducted the following activities:

• Review of technology and possible roadmaps
• Identification of potential products and markets
• Market segmentation and market opportunity assessment
• Competitive analysis
• Identification of, and interviews with future users and key stakeholders (including key opinion leaders)
• Identification and development of product requirements
• Creation of R&D plan and commercialisation strategy