May 29, 2024
Medical Devices
PCB Layout
Hardware Design
Building the Future of Medical Logistics with Invensify
How Whizz Systems Designed, Engineered, and Manufactured Invensify’s Next-Gen Cold Chain Solution
Whizz Systems is a trusted partner in medical device innovation, providing end-to-end electronic design and manufacturing solutions. In collaboration with Invensify, we developed Insuridge, a smart cold chain medical refrigeration system designed for precision temperature control and real-time monitoring.
Introduction
Innovating Medical Device Development in a Competitive Market
In the fast-evolving field of medical devices, partnering with a trusted development expert is critical. Whizz Systems has built a reputation for delivering end-to-end product development services—ranging from hardware design and PCB layout to thermal management and mechanical design—that drive innovative, high-quality solutions. This case study spotlights our collaboration with Invensify Inc. in bringing their groundbreaking Insuridge 12L, a portable refrigeration system designed for the safe transportation of sensitive medical drugs, from concept to reality.
Client Background
About Invensify Inc.
Invensify Inc., a cutting-edge startup based in Santa Clara, California, is dedicated to revolutionizing the transportation of temperature-sensitive medical products. By replacing traditional refrigeration systems with energy-efficient, environmentally friendly solutions, Invensify serves biopharmaceutical, healthcare, and logistics companies—ensuring that critical medical supplies reach their destination safely and reliably. Their innovative products have the potential to extend into the EV and AI hardware markets, further demonstrating their versatile approach to technology.
Product Overview
Introducing Insuridge 12L: A Next-Generation Medical Device
Invensify’s Insuridge 12L is a semiconductor-controlled portable refrigeration system designed to maintain a strict temperature range (2°C to 8°C) for sensitive medical drugs over extended periods (up to 100 hours).
- Precise Temperature Control: Maintains optimal conditions for pharmaceutical integrity.
- Energy Efficiency: Consumes less than 0.24 kWh per day.
- Robust Construction: A 12-liter payload capacity in a single, durable enclosure.
- Advanced Connectivity: Integrated LTE, GPS, and Bluetooth for real-time monitoring.
- Rapid Cooling & Charging: Incorporates a high-performance liquid cooling system and phase change material (PCM) to extend thermal stability.
How Whizz Systems Delivered
Hardware Design Engineering
An intelligent charging circuit was developed to balance external power and battery use. Whizz Systems designed a circuit capable of powering the system directly from external input, supplementing additional power from the battery when necessary.
A feedback-based electronic circuit was also incorporated that regulated the peltiers & cooling system with help of sensors. Moreover, to ensure reliable monitoring, GPS module with cellular connectivity was also integrated that enabled real-time tracking and secure cloud data transmission.
PCB Design & Layout
Insuridge required a compact and high-density PCB design to fit all components without compromising functionality. Modular and space-efficient designs were employed to maximize space while ensuring performance. Additionally, the PCB design incorporated various technologies, including analog, digital, power, and RF circuits, each requiring careful planning and design considerations.
To ensure reliable connectivity, Whizz Systems employed advanced layout and shielding techniques to prevent interference between the GPS, LTE, and BLE modules while also keeping the cost minimum.
Mechanical Design
The form factor and size of the overall product made it challenging to fit all components, including the PCBs, cooling chamber, payload and cooling system, in the unit. The limited available space further complicated the piping of the cooling system. From mechanical design perspective, fittinng all components within the given form factor without compromising the product’s functionality became very challenging.
To address this challenge, Whizz Systems utilized advanced 3D tools to thoroughly inspect and resolve potential interferences between assembled parts. This process ensured proper clearances around PCB components and mechanical enclosure, and provided adequate spacing for larger components like radiators and fans.
Through collaboration and iterative process, Whizz & Invensify achieved a design that smoothly integrated all elements without compromising the product’s functionality, while also ensuring manufacturability and ease of assembly.
Structural Analysis
Using Finite Element Analysis (FEA), we reinforced the plastic housing to balance weight constraints with the need for structural integrity. Reinforcement ribs and optimized design features ensured the enclosure could withstand shock and vibration without compromising the device’s overall performance.
To ensure structural integrity, we used Finite Element Analysis (FEA) to identify potential weaknesses in the plastic enclosure. Based on the analysis, reinforcing features like ribs were added to reduce stress and deformation, enhancing resilience against shock and vibration.
Liquid Cooling System & Thermal Management
The liquid cooling system of Insuridge consisted of phase change material (PCM), a cooling block, a radiator and an interconnected piping network. The PCM was crucial in maintaining a consistent thermal profile throughout its operation.
To optimize the PCM’s volume, a series of validation tests were conducted in the lab. The empirical data gathered from these tests were then used to refine and optimize the design of the PCM chamber. Additionally, thermal simulations were carried out to verify the experimental findings and ensure the reliability of the design.
The liquid cooling block, featuring internal fins and flow channels, was specifically designed to maximize cooling efficiency. Extensive flow simulations were conducted to develop an optimized design that struck the right balance between cooling performance and overall pressure drop.
Component Engineering & Supply Chain Management
Whizz Systems provided crucial support in component sourcing and supply chain management, developing an Approved Vendor List (AVL) to ensure the selection of high-quality, reliable parts. This proactive approach ensured continuity and quality across all phases of product development.
During the supply chain and component engineering phase, Whizz Systems developed an Approved Vendor List (AVL) to help Invensify identify and qualify suppliers capable of consistently meeting their requirements. Additionally, Whizz Systems identified secondary sources for critical components based on design specifications, ensuring continuity and preparedness in the event of primary source unavailability.
Ready to Accelerate Your Medical Device Development?
Partner with Whizz Systems for complete product development support. Our expertise in design, engineering, supply chain management, and manufacturing ensures that your medical device not only meets but exceeds industry standards—delivering faster time-to-market and unmatched reliability.
