Our customer required the design and production of a unique, self contained plastic magazine containing a cumbersome X-ray plate and filter which could be placed quickly, easily and precisely under a patient lying on a hospital gurney. The magazine could not appear as a foreign object when the X-ray was exposed in a darkroom.
Working closely with our customer we developed the X-ray plate holder using lightweight ABS plastic. The magazine is light weight, has rounded corners that won't tangle in patients' clothing, and has handles on three sides for convenient carrying. This combination enables it to be easily and precisely placed under the patient. We developed the tooling and are currently producing the magazine in quantity for our customer. It has markedly improved efficiency in X-ray film handling.
Different size cardboard and standard plastic parts handling trays ("tote boxes"), used for factory automation, would not stand up to continued use. This represented continuing replacement expense to customers as well as slowing down production lines. One of our customers, a distributor of these "tote boxes," was unable to obtain the custom, high quality boxes he sought from his regular suppliers and came to us for help.
We produced a "concept" in one day. Our design included a special clip to hold a bar code used for accounting as well as speeding up box movement. We delivered prototypes for approval in just twenty days. The tooling cost was under $3,800. Delivery of the first production run of 1200 units made of high density polyethylene was complete only five weeks after the order was placed.
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