From initial concept through to manufacture, Astramax represents the culmination of more than 3 years intensive R&D effort.

Brandon Medical’s existing theatre lighting range featured cumbersome products CNC’d directly from blocks of aluminium. A competitor analysis and market benchmarking exercise helped identify an opportunity for a lightweight, low cost surgical operating light. 

Brandon’s existing products featured a somewhat endless bill of materials and an assembly process totalling almost 8 hours.  As a result of this discovery, it was clear that value engineering would be at the heart of the design approach. 

 

Due to margins being progressively squeezed in export markets, a design for manufacture ethos became central in providing commercial justification for all design decisions.

Performance and ergonomic led parameters drove the design aesthetic, with the two developing concurrently.
Brandon’s new HD-LED internal technology allowed for a sleeker, lower profile housing than in previous halogen products, which was exploited in the concept ideation. 

The application of their two-tone blue & white brand identity helped enhance the illusion of a slimmer unit and combined with an intricately fluted clear lens undercarriage, assisted in obscuring the view from an otherwise unaesthetic interior.

Furthermore, the cellular-like LED lenses were mounted at converging angles to obtain a 1m focus point, driving a concave surface makeup on the lower lens moulding. This also removed any risk of a mirror effect on the underside of the product, preventing patients from viewing a reflection of their own surgery.

A great deal of work was carried out examining every part’s surface to remove as much material as possible whilst maintaining functionality and aesthetics. Proving out the 4.5kg weight limit of the concept was undertaken inside Solidworks, with studies on mass properties and centre of mass driving decisions on materials and honeycomb wall section designs.

Other aspects of the housing are equally novel, though less immediately apparent. The thin walled translucent blue lid features semi-permanent snap fits, so it can be removed on-site for essential maintenance.

on angled turrets made possible by flexible ejectors on the chassis mould tool.

All major fixings have been concealed with an intricate lens fluting design that also improves flow of material when injection moulding. The split lines of components were left loose in CAD and then tightened during moulding trials to eradicate dust collection, giving an IP54 rated housing. 

External components were manufactured in a V0 grade polycarbonate and then hard coated on-site for improved scratch protection and chemical resistance.

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