Accelerating Time to Market for Surgical Imaging Device with Enhanced Real-time Analysis
The Project
A medical-device startup needed to transform an early prototype into a next-generation surgical imaging platform, one that delivers real-time insight into tissue viability for safer, more precise resections. They engaged Forj Medical for multidisciplinary expertise across optical design, opto-mechanics, imaging electronics, and medical system architecture.
The Challenge
- Miniaturize the prototype into a surgical-grade camera head with user controls
- Sterilization-compatible cables, connectors & an ingress-rated lens focus mechanism
- Precision system tolerances for high-performance imaging
- Significant stray light to resolve from the initial prototype design
- Specialized, OEM-compatible materials, sourced without adding scale risk
- Seamless integration with the OEM’s existing control & imaging architecture
The Solution
- Custom imaging cell with a movable, sealed focus ring to protect internal components
- Custom silicone-overmolded cable for superior strain relief & compatibility
- Anodized coating on all components to survive repeated sterilization
- Stray light eliminated via system-level analysis, coatings, apertures, geometry
- IP67 testing + patient-isolated, low-latency electrical design
- DFM from day one, cost-effective precision parts, scalable assembly
