Design of a Medical Sharp Object Encapsulation Machine

employer:

Simut (MFP)

Design of a Medical Sharp Object Encapsulation Machine

Design of a Medical Sharp Object Encapsulation Machine

The Safety Box Destruction and Encapsulation Device, with its unique and functional design, offers an effective and safe solution for managing sharp and cutting medical waste such as needles and surgical blades. The device operates in two stages. In the first stage, the safety box is placed inside a thermal chamber where the temperature rises to between 160°C and 190°C, causing the plastic of the safety box to begin melting. Simultaneously, microbial, viral, fungal, and pathogenic spores are eliminated.

In the second stage, a hydraulic press system is used to compress the molten material, encapsulating the sharp objects inside. The result is a compressed, safe block that no longer poses any risk to people or the environment.

The industrial design and structure of the device are based on the principles of simplification and production optimization. The body is made using sheet metal fabrication from durable metals that not only ensure high strength but can also withstand intense heat and pressure. These sheets are designed in a way that keeps the overall structure both lightweight and robust, allowing the device to be easily transported using a crane or pallet jack. The design also ensures easy access to internal components, making maintenance and periodic servicing fast and simple. This minimizes downtime and maximizes productivity.

Moreover, the device uses reliable hydraulic systems that guarantee high performance and operational safety. It is designed to keep production costs low while maintaining the quality and durability required for use in industrial and hospital environments. The simplicity of the design has been considered throughout the entire process—from concept and production to operation—making it cost-effective, low-maintenance, and user-friendly for operators.

In summary, the Safety Box Destruction and Encapsulation Device is a comprehensive and economical solution for safe medical waste management, offering a simple design, easy transport, quick maintenance access, and high safety—perfectly meeting the needs of healthcare centers.

Challenges of designing the product

The device must be capable of withstanding high temperatures (160°C to 190°C) continuously without compromising structural integrity. The thermal system must be designed to be both safe and efficient, ensuring consistent performance under prolonged use.
The hydraulic press requires a robust mechanical structure to endure the high pressure generated during the compression and encapsulation of sharp objects.
The device body should be constructed from durable metal sheets that are both lightweight and strong, capable of withstanding mechanical loads and thermal stress.
The design must allow for easy transport and relocation using a crane or pallet jack, without causing damage to the device’s structure or functionality.
It is essential that operators have easy access to internal components for maintenance and periodic servicing. The design must provide adequate service space without requiring extended downtimes—this is one of the major design challenges.
The system must ensure operator safety during the destruction and encapsulation processes by preventing exposure to mechanical, thermal, or chemical hazards. Safety features such as thermal sensors and physical guards must be incorporated.
One of the key challenges is to reduce production costs without compromising on quality or performance. This requires careful material selection and optimized manufacturing processes.
The use of environmentally friendly materials in the device’s construction and the design of processes that minimize the generation of harmful waste are also essential design considerations.
Lastly, the device must be intuitively operable, ensuring ease of use for operators in real-world medical or industrial environments.

Properties of the final design

Ergonomic design of keys, gauges, and indicators based on users’ anthropometric data.
Consideration of assembly and disassembly scenarios to facilitate maintenance and periodic servicing.
Combined use of metal and plastic in the external design to balance durability and lightness.
Aesthetic design with modern forms aligned with the visual language of contemporary medical equipment.
Color scheme coordination with current trends in medical devices to evoke a sense of trust and hygiene.
Consideration of transport, relocation, and easy installation in diverse healthcare environments.
Design of washable surfaces resistant to disinfectants for easy cleaning and maintenance.
Creation of a distinctive and professional form identity that still aligns with other medical products.