Once COVID-19 spread to the United States, it wasn’t long before the domestic manufacturing market felt its effects.
An industry that relies heavily on international partners—specifically Asia in illuminated electronics—would need to recover by adopting business tactics that lean heavily on transferring work to suppliers that are geographically closer in an effort to control costs, increasing production flexibility, lowering supply chain risk and producing a skilled workforce.
With a nearshoring business strategy squarely in place, San Diego-based Visual Communications Company (VCC) was prepared for the supply chain shift. “The impact of the coronavirus is changing, and has changed, supply chain strategies,” said Andy Zanelli, president and CEO of VCC, which has been in the business of manufacturing illuminated electronic components.
VCC has been able to shed light on the benefits of sustained nearshore electronic manufacturing by using its creative solutions and collaborations supporting those in need of design and prototyping support during the current climate, explained Zanelli. In addition, the company launched a pandemic support initiative—Crisis ColLAB—to offer free design and engineering services to medical equipment providers and OEMs produce products that will help essential workers combat COVID-19.
The company had already donated thousands of light pipes and other components to be used in the global efforts to combat the virus, including crucial components for a device that would deliver a COVID-19 vaccine in development. But with expertise in engineering design for medical equipment; an experienced team of mechanical and electrical product designers and engineers eager to streamline production; the ability to design software for creating and testing solutions; access to 3D printing machinery; and proven performance in designing and prototyping PCB assemblies, light engines and other electronic components, the company had the tools and all the more reason to offer crisis collaboration services.
Light Pipes
In mid-April, a medical device OEM working on developing a COVID-19 vaccine enlisted VCC’s free design services through Crisis ColLAB. With speed being crucial to getting a vaccine approved and distributed, the device used an existing product footprint, creating constraints such as light power and energy consumption.
In a perfect world, VCC would have been able to design a solution from scratch. With the additional requirements of reliable operation, visibility from multiple viewing angles and accelerated timeline, the pre-existing device design created multiple challenges to developing three light pipes at different locations on the handheld device. As a result, getting the exact light pipe performance to meet design requirements was more complex than it seemed.
VCC’s design capabilities aligned perfectly with the needs of such a mission-critical assignment. Each RGB LED indicates a specific status, and at the time VCC received the device design, extreme light loss was impacting visibility and performance. VCC’s engineers ran multiple light simulations to optimize performance. The team ultimately replaced the original light pipes with custom designs that led to a total increase of 1,561% in efficiency while providing uniform illumination to improve the accuracy of operation. The three customized rigid light pipes facilitated communication at various status operations of the device including:
- On/off
- Charging
- In use/operation status
A textured surface was added to the end of each rigid light pipe to provide the uniform illumination needed for accuracy and specified snap-in and press-fit fittings to streamline product manufacturing and assembly. Multiple simulations were used to perfect the light pipes followed by 3D-prototype testing to evaluate proof of concept.
Seamlessly collaborating with the medical device manufacturer’s team, VCC was able to quickly reach a solution that exceeded the ask while providing safe, reliable operation from multiple viewing angles. All optical requirements and client goals were met and the concepting and analysis phase were completed at no cost to the client.
Social Distancing
“In order to maintain social distancing at all times and while developing the custom light pipes specifically, the team worked from home as much as possible,” said Zanelli. “When employees needed to go to the engineering lab, alternating shifts were taken to maintain worker safety. Light pipe samples were 3D printed in VCC’s lab to verify the concept along with 3D simulations, and all meetings, reviews, validations and other communications with the client were conducted via video calls.”
Waiting for a Vaccine
The COVID-19 vaccine is in development and must go through clinical trials and FDA approval before being distributed. Once the working prototypes of the vaccine delivery device are approved, the light pipes will be manufactured by June and will be ready for installation before the vaccine is ready. Once approvals are in place, the device is planned to launch later this year to help combat the virus.
VCC’s Zanelli notes that the vaccine delivery device demonstrates the need and the likelihood that manufacturers will want to have more autonomy and visibility over their supply chain in the future. “If this were to happen again—another pandemic, another trade war or something else—they will want the capacity to deal with that,” said Zanelli. “They can deal with this adaptation in a few ways, likely beginning with understanding what the true cost is to manage a global supply chain.”
Visual Communications Company (VCC) develops HMI solutions in the fields of aviation, transportation, industrial equipment, medical technology, energy technology, automation technology, consumer wearables and durable goods. The company’s range of standard components and assemblies include indicators, membrane switches, capacitive touch and LED displays. OEMs and medical equipment providers can inquire about Crisis ColLAB by completing the online form.