Case Study

Design of Fill and Seal Station for COVID-19 Point of Care Diagnostic Units

Project Snapshot

A client needed to quickly automate a process to scale up the production of a consumable component used in COVID-19 Point of Care Diagnostic Units. A machine was designed that automatically singulated components, filled them with saline, verified that the proper amount was dispensed using vision inspection system, sealed the component and verified the seal via another vision inspection system.

Project Challenges

Due to immediate need of the fully automated system to fill and seal the test kits, the project design timeline was extremely aggressive. Sterling was able to mobilize and assign design engineers to this project within 24 hours.
The design and detailing was accomplished by utilizing two shifts in less than 3 weeks, working over 1,000 hours.
Daily design reviews with all project leads were implemented, resulting in a synchronized, seamless workflow process.
Through collaboration, our client was able to respond quickly to meet deadlines in an accelerated timeframe.

Sterling’s Solution

Sterling’s team included 2 Project Managers which served as a liaison between client’s lead engineer and SEI design engineers. Project managers coordinated the design and detailing effort between 2 shifts that worked around-the-clock to compress the delivery schedule.
At the kick-off meeting, Sterling worked with the client to analize the source data of a similar stations and apply the knowledge to the design of the new stations for this particular application.
The system was designed with Solidworks 3D-CAD assembly models, detailed part drawings. These tools allowed Sterling to verify station operation and fitment into overall system resulting in a safe and efficicent process layout.
Because of the size of the design team required, Sterling’s team focused on producing the individual stations and locating them in main machine layout, full assembly drawings, bill of materials and detailed part drawings for release to manufacturing.

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