A customer in the medical industry contracted Fabco Manufacturing, Inc. to remodel and revamp the production procedures for the EasyCell hematology imaging system enclosure highlighted below. The initial product was unable to pass FDA standards due to inadequate EMI shielding and a plastic casing. Their alternative coatings and material additions were proving to be too expensive to stay competitive in their market. We were able to re-engineer their product, reverse engineering and applying cost analysis to the customer-supplied sample in order to arrive at a cost effective and functional solution.

The unit was redesigned, abandoning the plastic for an aluminum body construction. Employing our developed precision manufacturing capabilities, processes including shearing, punching, laser cutting, forming, TIG and spot welding, grinding, and machining were applied to aluminum material to form the unit, holding tight tolerances throughout. Powder coating and silk screening were applied to the part, and hardware was inserted where required for completed assembly. Overall finished dimensions of the enclosure were 24” in width, 18” in depth, and a height of 12”. The part was tested with first article inspection, dimensional inspection, as well as EMI testing and certification. Turnaround time for this project was 4 weeks, and we produce 300 units per year for this client, located in Massachusetts. The redesigned aluminum enclosure was an ideal solution for the customer’s initial dilemma, providing a reduction in cost and eliminating the EMI shielding problem. For more details about this EasyCell medical device design project or any of our other manufacturing and design capabilities please see the table below or contact us directly.

Hematology Imaging System Project Highlights

Project NameHematology Imaging System (EasyCell Assistant)
Project DescriptionThe customer could not sell their product domestically due to Electromagnetic Interference (EMI). The enclosure was made of plastic and did not contain the EMI shielding necessary to pass FDA guidelines. Fabco Manufacturing was asked to provide options for shielding the EMI and determined that scrapping the current plastic enclosure and building the unit out of aluminum was the most cost effective and practical solution.
Capabilities Applied/Processes
Reverse Engineering
Design – SolidWorks Models and Drawings
Cost Reduction Studies
Laser Cutting
TIG Welding – TIG and Spot
Powder Coating
Assembly – Hardware Insertion
Overall Part Dimensions Width: 24”
Depth: 18”
Height: 12”
Material UsedAluminum
Material Finish Powder Coated and Silk Screening
In process testing/inspection performed First Article Inspection, Dimensional Inspection
Electromagnetic Interference (EMI) Testing and Certification
Industry for UseMedical Device, Laboratory Test Equipment
Volume300 units/year
Delivery/Turnaround Time4 Weeks
Delivery LocationMassachusetts
Standards MetCustomer Specifications, 2D CAD Drawing
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