Requirements: 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.
Performance: • 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.
Result: • 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 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.