Complete Medical Device Design

The Arrow LVAD (Left Ventricular Assist Device) power management module, explode view.    

The Arrow LVAD Controller


The mechanical design challenge: Create an easily assembled structure for the electronics and circuit boards of the LVAD Controller.  
  •  All of the molded parts to be single action
      injection molds, with no slides.
  •  Significant performance and battery life
      improvements may drive significant
      component changes, mid-design.  
  •  A radiused rectangular solid with three
      circuit boards connected by flex conduit.
  •  Size envelope fixed at previous power
      supply minus 1" on 2 of 3 dimensions.

  •  Mold simplicity maintained through creative draft angling.
  •  Parametric modeling assured rapid and error-free mid-project component resizing.  
  •  Interlocking mechanical supports kept device volume to a minimum, while maintaining high
      structural integrity.  
  •  Selective mating part flexure and internal springs capably offset stack-up tolerances.  
  •  Prevented electrical component interference by modeling of printed circuit boards, and identifying
      component interferences correction prior to production,
      preventing a subsequent circuit board build.

  •  Internal structure was sound.
  •  Assembly was intuitive.
  •  Structural HALT testing was a complete success.
  •  The mechanical support structure was produced on spec, on cost, and on time.

         This was an LVAD (Left Ventricular Assist Device) power supply, which would process all of the power for the LVAD Pump, and store over 20 minutes of power internally.  
                                       This is an image that I produced of the complete laser welded enclosure. 

This is an illustration of the previous version of this device, and its location in the patient.

NOTE:  Images used with permission.