My First Big Win: A Younger Engineer’s Medical Device Triumph

medical device design win

I’m Alex, an Associate Partner at DDI. Early in my career, I had the opportunity to lead my first significant medical device project—a hospital-use pump that demanded both high-level functionality and compelling aesthetics. Looking back, my biggest takeaway from that experience was the invaluable power of leaning into feedback early and often.

What Happened:

We poured our energy into the initial design, and on screen in CAD, our prototype looked fantastic. However, the moment we held the physical reality in our hands – a 3D-printed prototype – it became clear that several angles and overall proportions were simply unattractive. The disconnect between the digital model and the physical form was striking.

Recognizing this discrepancy, I immediately scheduled quick feedback sessions with a cross-functional team. The insights we received during these sessions were truly eye-opening. Different perspectives from engineering, marketing, and even potential users highlighted aspects we had completely overlooked.

Armed with this crucial feedback, we embraced rapid iteration. Our first step was to revisit the electro-mechanical package, meticulously reworking it to reduce any unnecessary internal volume. This seemingly internal adjustment had a significant external impact. By optimizing the internal layout, we were able to jump back into the surface model and reduce the overall size of the device by approximately 20%.

What was particularly remarkable was the visual impact of this size reduction. Because our eyes perceive volume rather than linear dimensions, a ~20% reduction in the X, Y, and Z maximum dimensions made the device appear to be about half its original size. The aesthetic improvement was far more dramatic than the numbers alone suggested.

Result:

The updated prototype was met with enthusiasm. Our client was incredibly pleased with the refined design and confidently moved the project forward to the next stage. Following this success, DDI was able to produce a fully functional proof-of-concept prototype for crucial clinical evaluation.

Why It Matters:

This experience taught me a profound lesson: early missteps don’t spell the end of a project—as long as you have the humility to identify them, the ownership to acknowledge them, and the agility to act fast. My initial “perfect” CAD designs, created in isolation, were consistently trumped by the practical, real-world insights gained through collaborative feedback. Embracing that feedback early not only saved time and resources but ultimately led to a far superior and successful medical device.

Are you looking to bring your medical device ideas to life with a team that values early feedback and rapid iteration? At Design Department, we believe in a collaborative approach that leverages diverse perspectives to create impactful solutions. Let's discuss how we can help you navigate the design process effectively.

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