Value engineering for YAG ophthalmology laser

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Starting situation

Due to obsolete electronics and laser components, an ophthalmology device manufacturer has commissioned IMT to redesign an existing laser therapy device. Using laser photocoagulation, this device can treat many retinal diseases. The redesign is expected to reduce manufacturing costs and ensure manufacturability for years to come. The redesign should not require the device to be re-approved.

Objective of the project

  • Reduce manufacturing costs by 25%
  • Replace discontinued components
  • No visible change from the outside
  • Comply with RoHS Directive
  • Revise documentation to meet IEC 60601-1 3rd Edition criteria for approval

Technical implementation

Manufacturing costs were successfully reduced with the following changes:

  • A new high-power, diode-pumped solid-state laser with a wavelength of 532 nm was used.
  • The optical beam guide has been redesigned without a deflection mirror.
  • The safety shutter design has been simplified.
  • The main electronics of the laser therapy device are completely redesigned and a new power supply concept has been introduced.

We were able to significantly reduce power dissipation in the electronics by using more efficient and more modern components. In addition, a new thermoelectric cooling unit with a control deviation of less than 0.2K has been implemented. This ensures the highest temporal stability of the laser power – a basic requirement for reproducible clinical results.

The changes made to the design have significantly simplified the production of the device, resulting in the decreased assembly time.

Results

Manufacturing costs have been reduced by the required 25% through the optimal interaction between system design, electronics development, and mechanical construction. Process reliability during production increased simultaneously and conformity with standards was achieved. By replacing obsolete technology, manufacturability has been secured for the future.

“Both the client and IMT were amazed at how much cost reduction potential there was in an existing device. We made the most out of this opportunity.”

Martin Anrig, Projektleiter

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