LensAR Femtosecond Laser System

Role: Senior Industrial Designer
Company: Bleck Design Group
Years: 2010
Expertise: Industrial design, Rhino, Prototyping, DFM, Engineering Collaboration

Overview

The LensAR Laser System is a sophisticated ophthalmic laser platform developed for cataract surgery. My role focused on transforming an established design direction into a production-ready enclosure that balanced aesthetics, ergonomics, serviceability, durability, and manufacturability.

Working closely with the client and engineering team, I developed the complete exterior enclosure from concept models through detailed CAD, ensuring the design was refined for manufacturing while maintaining the original design intent.

 

Design Challenge

The laser's internal components and functional architecture had already been engineered. The challenge was to design an exterior enclosure that integrated around the existing hardware while creating a professional medical appearance and meeting the demanding requirements of a clinical environment.

Key design objectives included:

• Clean, modern aesthetics appropriate for a premium medical device
• Easy access for servicing and maintenance
• Durable construction suitable for everyday clinical use
• Surfaces that could be cleaned and disinfected easily
• Comfortable ergonomics for operators
• Manufacturable geometry suitable for production

 

My Role

I was responsible for the industrial design development of the exterior enclosure after the initial concept direction had been established.

My responsibilities included:

• Translating concept sketches into accurate three-dimensional models
• Building scale appearance models from urethane foam for client presentations
• Developing the complete enclosure in Rhino
• Designing and refining exterior components for manufacturability
• Producing full-scale ergonomic mockups of user interface components to evaluate comfort and usability
• Iterating the design through multiple client review cycles
• Delivering production-ready CAD geometry for engineering implementation in SolidWorks

 

Design Process

Physical Model Development

Initial design concepts were translated into scale urethane foam models that allowed the client to evaluate proportions, form, and overall appearance before committing to detailed development.

CAD Development

Following concept selection, the enclosure was developed as a complete Rhino model. Every exterior component was refined while considering manufacturing constraints, assembly methods, durability, and serviceability.

Ergonomic Evaluation

Critical user interface components were produced as full-scale physical mockups to evaluate comfort, reach, and overall usability before finalizing the geometry.

Design Refinement

Several rounds of design refinement were completed in collaboration with the client to optimize aesthetics, functionality, and manufacturability while preserving the original design intent.

 

Results

The finalized industrial design was approved by the client and transferred to engineering for production development. Rhino geometry was delivered for recreation in SolidWorks, supporting the transition from industrial design to manufacturing engineering.

• This project strengthened my experience translating conceptual design into manufacturable products while balancing aesthetics, engineering constraints, usability, and the practical requirements of medical equipment used in clinical environments.

 

Skills Demonstrated

• Industrial Design
• Medical Device Design
• Rhino
• Physical Prototyping
• Ergonomic Evaluation
• Appearance Modeling
• CAD Development
• Design for Manufacturing
• Engineering Collaboration
• Client Presentation