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Team LiteCure. Dhara Amin , Michael Brennan, Eric DiBlasi , Andrew Smith. Background. LiteCure : Manufacturing company for medical devices involving advanced laser technology for the health care and veterinary industries.

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dhara amin michael brennan eric diblasi andrew smith

Team LiteCure

DharaAmin, Michael Brennan, Eric DiBlasi, Andrew Smith



  • LiteCure: Manufacturing company for medical devices involving advanced laser technology for the health care and veterinary industries.
  • Products: Deep tissue therapy units that use laser technology to accelerate the body’s natural healing process.
  • Products are typically housed on a cart to allow the device to be transported from one patient to another in clinical settings



  • Poor fiber optic and power cord management
  • Lack of accessory storage and securing of those accessories
  • Aesthetic image of the cart
  • Ease of use and functionality improvements

LiteCure is in need of a custom cart design that solves several problems surrounding their current cart design.

Current LiteCure Cart


Project Scope

To design an aesthetically pleasing utility cart for LiteCure’s deep tissue therapy unit that coincides with their desired image and allows users to easily access and store all components of the unit in a clinical setting.

Deliverables For Sponsor

  • Full Drawing Package of Final Concept
  • Manufacturing Details
  • Assembly Details
  • Prototype

Product Line

15 Watts 9 watts

12 watts 10 watts


Hand Piece and Fiber Optic Cord

Hand Piece

  • Fiber Optic Cable:
    • 3 meter length
    • Minimum bend radius of 3 inches

Product Accessories

Patient Glasses

Operator Glasses

Laser Head Attachments

“Doggles” (Veterinary Use)

UPS System

Foot Pedal (10 Watt Unit)



Anthro Cart

UD PT Clinic

Anthro Cart

Vet Hospital

Cutting Edge K-Laser


Design Requirements

  • Compatible with product line
  • Aesthetically pleasing
  • Low cost
  • Easy to use
  • Safe

Our Process



Preliminary Designs

Final Design

Sponsor Feedback

Final Prototype

Design Details


Basic Component Design

  • Platform:
    • Where the units sit
  • Structure:
    • Body of the cart
  • Base:
    • Bottom of the cart: Where UPS sits
  • Caster Selection:
    • Caster size, type, and vendor
  • Accessory Design:
    • Compartments for: Fiber Optic Cable, Safety Glasses, Foot pedal, Head attachments

Caster Selection

Single Wheel Caster

Thermoplastic Polyurethane Polyolefin

Thermoplastic Elastomer

Twin Wheel Caster

Structure and Wheel Material


Caster Selection

Top Plate Threaded Stem Grip Ring Stem

Other Considerations:

  • Wheel Diameter: 3 or 4 inches
  • Locking Wheels: yes or no
  • Swivel: yes or no
  • Load Capacity: at least 50 lbs
  • Warranty: at least 2 years

Fastening Type:


Manufacturing Research

  • Anthro:
    • Materials used for shelving
    • Capabilities of a wood laminate design
    • Cart structure material
    • Minimal welds in design
  • Extreme Machining:
    • Press breaking capabilities
    • Tube bending practices
    • Water and laser cutting capabilities

4th Iteration Design

  • Chose C-shaped structure
  • Added a locker
  • Incorporated the feel and lines of the LiteCure devices
  • Material: Carbon steel sheet metal


  • Material: Wood
  • Casters: 4-inch and 3-inch
  • Standard hardware
  • Mockup used for the following purposes:
    • Perform tipping and rolling test
    • Evaluate casters
    • Perform field test (in PT clinics)
  • Results:
    • Increase length and decrease width of platform
    • Front door design

Customer Review

  • Design: UD PT Clinic and LiteCure office used mock-up for three days and took survey.
  • Customer review measures:

Customer Review

  • Results:
    • Aesthetically appealing
    • Functional
    • Satisfactory cord and fiber optic cable management

Customer Review results for the questions asked about cord and fiber optic cable management. The mean values for the question are represented with correlating standard deviations.

Survey Scale: 1 –Strongly Disagree , 2 –Disagree, 3 –Neither Disagree nor Agree, 4 –Agree, 5 –Strongly Agree


Final Design

  • Material: 14 Gauge & 16 Gauge Carbon Steel
  • Casters: 4 inch diameter
  • Fasteners: PEM fasteners
  • Features: Back locker, front door
  • Storage space: 1.9 ft^3
  • Height: 30 inches
  • Weight: 65 pounds

Final Design: Aesthetics

  • C – Shaped cart with curves and lines similar to LiteCure devices
  • Color scheme can be used for both product lines
  • Space for logo
  • Finish: Powder coated paints
  • Larger 4 inch casters

Final Design: Platform

  • One size platform for multiple devices
  • Refined dimensions
  • Perimeter around device
  • Hole for cord management

Final Design: Structure

  • Wide base for stability
  • PEM fasteners attach all parts
  • Flanges on shelves add strength
  • Converged to aesthetic design based on sponsor feedback

Final Design: Additional Features

  • Front Door:
  • Easy access to goggles and head attachments
  • Goggles stored in mesh bag on front door
  • Speed controlled hinge
  • Back locker
  • Easy access to all shelves
  • UPS and miscellaneous storage space
  • Rotating latch

Final Design: Additional Features

  • Fiber Optic Management
  • Hook design
  • Quickly drape cord over hook
  • Secure hand piece on device
  • Power Cord Management
  • Hole in top platform
  • Hole in back locker door
  • Internal guide for cords

Cost Analysis

  • Quote of 1 Cart (machine shop)
    • $1460
    • Does not include: PEM Fasteners, McMaster Hardware, Casters, Front Handle, and Fiber Optic Cable Management Hook.
  • Quote for 1000 number of units (machine shop)
    • $200 - $225 a unit
  • Hardware Cost: About $31 a unit
  • PEM Fastener Cost: About $30 a unit
  • Casters Cost: About $34 a unit

User Instructions

  • Assembly
  • PEM fasteners press fit in to side panels
  • Detailed instructions for assembly
  • Only 1 tool needed: Wrench
  • Packaging
  • Cart can be broken down in to smaller, flat parts
  • Box dimensions: 27.5 in x 27.75 in x 6 in

Path Forward

  • Give LiteCuredrawing package and assembly instructions.
  • LiteCure can take design to manufacturing company for start of mass production.
  • Small changes may need to be made to the design in order to be manufactured by a specific company.
  • More testing to sheet metal prototype: accelerated wear and overload testing