AltaSim Technologies helps clients bring products to market faster and at lower cost through advanced multiphysics simulation. This case study highlights how our simulation expertise helped a medical device manufacturer identify and resolve a critical performance issue.
Problem:
A manufacturer of a leading biopsy instrument was receiving increasing feedback from surgeons that the device occasionally failed to return a tissue sample. Concerned about potential underperformance, the client conducted extensive experimental testing to identify the conditions that led to these zero-sample cases.
However, the instrument’s operating method made it difficult to collect the necessary data during physical testing. As a result, the client was unable to isolate the root cause, modify the product design, or provide clear guidance to surgeons to mitigate the issue.
Solution:
AltaSim developed dynamic COMSOL Multiphysics® simulations of the device’s mechanical operation, including contact interactions between multiple components and elastic springback of a plastically deformed part. These simulations allowed the client’s engineers to directly observe the internal behavior of the device during operation—insight that was not achievable through experimentation alone.
By systematically varying key design parameters, AltaSim identified the specific combination of factors that produced zero-sample outcomes. A detailed review of the simulation results by AltaSim and the client’s engineering team led to a clear understanding of the underlying failure mechanism.
Results:
With a $25,000 investment in AltaSim and leveraging our engineers’ experience in complex mechanical simulation, the client successfully identified the root cause of the increase in zero-sample cases. Through simulation-driven analysis, they isolated critical variables and quantified their impact on device performance.
Armed with these insights, the client’s engineers developed a modified manufacturing method that significantly reduced zero-sample occurrences and helped restore the quality and reliability of a long-standing product.
AltaSim partners with companies to provide simulations that increase the knowledge and understanding of our clients’ engineering staff. By working collaboratively with our clients, we help translate simulation insights into actionable solutions for complex engineering challenges. To learn more about our simulation services, click here. To speak with our team directly, please visit our Contact Us page.
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