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Reverse Engineering

Autoclave Case Study: Redefining Sterilization Performance

Category

Design for Manufacturing

Client​

Inlab equipments

Overview

In today’s competitive environment, precision and efficiency are critical—especially when it comes to ensuring sterilization standards in the healthcare and research industries. Our recent project on reverse-engineering autoclaves exemplifies our commitment to innovation. By meticulously deconstructing and analysing existing models, we were able to reimagine the design, enabling enhanced sterilization performance through improved mechanical engineering and manufacturing processes.

The Challenge

Autoclaves are integral to sterilizing medical and laboratory equipment, but traditional models often face issues related to design inefficiency, manufacturing complexities, and system reliability. Our client needed a solution that would not only address these challenges but also deliver consistent, robust performance in sterilization without compromising on safety or quality. The key challenge was to develop a comprehensive redesign that optimized every aspect—from mechanical drawings and BOMs (Bill of Materials) to the manufacturing process—ensuring each component contributed to superior efficiency and reliability.

Our Approach

To tackle these challenges head-on, our engineering team embarked on an in-depth reverse-engineering process. Key steps in our approach included:

We conducted a thorough evaluation of the existing autoclave designs to pinpoint inefficiencies and areas for improvement. This granular assessment allowed us to understand the intricacies of thermal distribution, pressure dynamics, and material stress points.

 

Based on our findings, Clicky implemented a series of design enhancements aimed at maximizing performance. We provided updated mechanical drawings that integrated advanced engineering principles, making it easier for manufacturers to produce each autoclave with tighter tolerances and higher quality control.

 

We overhauled the BOMs to include parts that improved durability and functionality while reducing costs. Our revised manufacturing designs were optimized for efficiency, ensuring that production processes were both reliable and scalable. This method not only improved overall through but also reduced downtime and waste.

 

Prototypes were rigorously tested under various operational scenarios to guarantee that the new design met and exceeded industry standards for sterilization. Feedback from these tests was used to make fine adjustments, further enhancing performance reliability.

 

Results and Impact

Enhanced Sterilization Efficiency:
The redesigned autoclaves delivered consistent sterilization performance, ensuring that every cycle met rigorous safety standards.

Improved Manufacturability:
With a refined set of mechanical drawings and a streamlined BOM, manufacturers found it easier to produce the autoclaves, reducing production time and cost.

Reliability and Durability:
The focus on system reliability translated into autoclaves that not only performed better out-of-the-box but also maintained peak performance over extended use, reducing maintenance requirements.

Broad Industry Applications:
The improvements have created a platform for use in various sectors, including healthcare, laboratories, and any industry where sterilization is paramount.

Conclusion

This project demonstrates our ability to transform traditional equipment through innovative engineering. By rethinking every aspect of autoclave design from mechanical components to end-of-line manufacturing—we delivered a product that redefines sterilization performance. Whether you’re looking for enhanced efficiency or greater reliability in your sterilization processes, our case study with Clicky serves as a prime example of how detailed analysis and forward-thinking design can meet even the most stringent industry demands.