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User Experience

Product optimization through design review

In this design review, Zühlke examined the reliability of production and substantially improved the use characteristics of a medical product.

Customer Benefits

  • Increased safety and better quality of the product.
  • The design was optimised during the development stage.
  • Know-how gain from the knowledge of the Zühlke team.


Over 120 million people suffer from type 2 diabetes worldwide. Many of them have to take blood samples daily. Patients are given finger-pricking devices to help them carry out these procedures easily and painlessly. These devices must operate extremely reliably and are produced in large quantities. In this project, Zühlke’s task was to review the design of a new generation of these devices before they were approved for mass production. The manufacturer wanted to launch the product on schedule and in accordance with high quality standards.


The review team started by reviewing the safe operation of the device. This product is made almost completely out of plastic. Careful attention was therefore paid to the material selected and pairings and to whether the design was appropriate for the material (wall thicknesses, back-cuts at curves). Critical components (e.g. springs) were examined with FEM for possible overstressing and tolerance chains were re-calculated (statistically and worst case). The Zühlke engineers passed their review findings on to the developers on an ongoing basis, so the latter could make immediate improvements in the design. A second priority was the readiness of assembly. Experts used MTM methods (Methods/Time Measurement) to optimise the assembly and calculate the assembly time.


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Photo: Mr Gino Burro

Gino Burro

Senior Business Development Manager

"More and more patients and physicians look for innovation and usability in medical products - customer enthusiasm is necessary for your differentiation. New markets open up and product approvals need to be attained fast. Let us develop your digital strategy together!"
Photo: Mr Claudio Schödler

Claudio Schödler

Business Solution Manager