LENSAR Laser System

Bleck Design Group, LensAR Laser System

Bleck Design Group designed the external enclosure for this new ophthalmic laser. This medical device automates the removal of a patients natural lens prior to implanting an artificial lens (capsulotomy). This allows a reduction in surgical time and cost.

Concept Rendering for Investors: The project started with developing a concept rendering for investors. The goal of this phase was to illustrate the basic system and show investors and users the overall concept

User Survey and Ergonomic Design: Next we surveyed the ophthalmologists and developed the ergonomic concept for controls and patient interface. We completed anthropometric analysis to set ideal ranges of motion and resolved conflicts between the ideal range of motion and the prototype laser optics and electronics. We completed user reviews by taking a mock-up to several ophthalmologists offices and confirming the design would meet constraints. 


Industrial Design: Bleck Design Group then developed a range of industrial design concepts and selected a design direction. We refined this design in scale models and computer renderings of the external form then completed a preliminary engineering layout 


Transforming the Concept to Production: We then had four months to complete the production design of all the parts, fabricate a model and have the assembled final prototype at an annual trade show. In eight weeks our design and engineering teams designed over thirty five complex assemblies, coordinated fabrication across the country, and merged all the parts together, on schedule for the final product assembly.


Production Design: We then transformed each prototype part into a production ready design and released to production tooling. We managed the vendors and continued to fabricate prototype parts. Finally we transferred our documented design to the client's manufacturing group.

Soteira Surgical Instruments

Bleck Design Group, Soteira Drill Reamer Combo


This product drills and reams a cavity in a fractured vertebra to allow the placement of a stent which is then filled with injected adhesive.

An Ergonomic and Cost Problem: The original design performed the drilling and reaming with required precision and control. However this required two devices, careful set-up between drilling and reaming, and was costly. Training was time consuming as each language required new instructions.

Project Summary: Bleck Design Group combined the original two tools into one, improved the ergonomics and reduced cost over 50%. The original 15 steps were reduced to 4. In the new design, each action has a distinct control, with interlocks for safety.

Ergonomic Task Analysis and Mechanism Creation: The concept development focused on the external perception of the controls and creating corresponding internal mechanisms. The original threaded mechanisms were actuated with new cams,clutches and simple transmissions.

Transforming the Concept to Production: From concept to the first full prototype was four months. In six months the new design was validated and ready for clinical use.. The prototype was designed for low volume production and allowed Soteira to meet their market introduction. 

Production Design: The production design followed the initial pilot production. We released a revised version for tooling and supported the contract manufacturer through final validation.

SQUID Active Cold Compression System

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Portable Therapeutix is a Texas-based medical device company founded by an accomplished team of entrepreneurs and sports medicine experts.  SQUID, the company's first product, is an innovative cold compression therapy device for the treatment of joint or muscle pain. Portable Therapeutix hired Bleck Design Group to help them create a new product using their patented sequential compression wrap technology. 

This product is an excellent example of how we work as a startup's virtual product development team to commercialize their cutting-edge technology. Bleck Design Group provided a complete set of startup company product development services, including: concept development, industrial design, engineering, manufacturing selection, and FDA application support. We collaborated with their management, scientists, and athletic trainers to create a compelling design by optimizing the product's ergonomics for patient comfort and clinical results. 

This device is simple, easy-to-use and provides the highest level of performance, comfort, and efficacy for athletes and arthritis sufferers.  The result is a user-friendly and highly effective product with the shortest treatment time available on the market.


BIS VISTA Monitoring System: Aspect Medical Systems

Bleck Design Group, Aspect Medical BIS VISTA Monitoring System

Bleck Design Group collaborated with Aspect Medical System's team to design the BIS VISTA Monitor. The result is a space-saving design with an easy-to-use touch screen. We provided user research, industrial design, design for manufacturing, and on-going consulting and evaluation of engineering details.

Bleck Design Group improved ergonomics, manufacturing cost and reliability in this Senticare Pill Station®: Home Care Pill, Bleck Design Group connector system. We improved the ergonomics by adding design features to guide the users intuitive understanding. Through FEA analysis, simplified assembly concepts, and improved tooling the quality and manufacturing yield improved. We provided user research, ergonomic design, industrial design and mechanical engineering through production.

BISx System – This device provides critical signal processing to the sensitive sensor data from Aspect's patient senor. Bleck Design Group developed the design to meet flexible requirements for pre and post operative environments. The round shape dissipates heat and can withstand being caught under a patient bed. The round perimeter is easier to water proof. The contrasting color makes the device easy to find in any color field.

Senticare Pill Station®: Home Care Pill Dispenser

Home medical product design - SentiCare PillStation, a monitored pill dispenser

The Pill Station® by Senticare is a home based monitored pill dispenser. This Pill Station® helps a patient comply with drug regiments and avoid expensive hospitalization due to over and under dosage. Senticare conceived of a call-center based communication link in order to monitor home-care patients with critical medications. The PillStation® has a scanning camera that takes a picture of the pill tray contents and sends this to the call center. The call center then compares this picture to the patients drug plan. A speaker and microphone provide a one touch link to the call center. A display and signal light provides additional communication.

Start-Up Program

Bleck Design Group provided Senticare a complete Start-up set of design services. This represents our classic set of services that help new companies launch ground-breaking innovative products.

Founders and Investors

We helped the founders explain the design to investors and estimate the development costs. The concept was illustrated in models and drawings to provide an easy to understand product explanation.

Definition and Specification: Users were researched through interviews and presenting alternative concepts. Technology and components were selected, evaluated and transformed into feasibility models. User needs and technology were considered to make trade-offs and optimize performance and cost.

Concept to Production: Bleck Design Group provided industrial design, mechanical engineering, prototypes, and production sourcing. We provided a virtual design and engineering department for Senticare and worked as a part of their team as the design entered manufacturing.

Pill Tray - User Centered Design

The PillStation® has a novel (patent pending) pill tray designed to meet a wide range of behaviors in active patients. 

Bleck Design Group designed PillStation for easy use by elderly patients.    

Filling the Bin: Research showed patients and caregivers often organize medication once per week by sitting at a table and carefully loading each dose. Sitting at the PillStation would be impractical. So the entire weeks pills are snapped into a removable frame. This allows a caregiver to sit down at a table and carefully organize the doses.

Patient Impairments: Patients often have impaired vision, reduced tactile sensation or arthritis. The daily bins snap into the frame and have a large "push" button to eject the tray. The tray has three chambers (AM, Noon, PM) with individual doors allowing easy access the pills. The doors have large easy to grab handles.

Monitoring: The tray is placed in the PillStation®and a picture is taken of the pills by a camera and lighting that move behind the seven daily bins. This creates a recorded picture of the tray contents that is sent by a telephone connection to a call center. The call center then quickly reviews the tray status and compares this to the plan.

Communications: A speaker, microphone, graphical LCD and signal light provide easy to understand communications. One button push connects the patient to the call center for help. Positive messages arrive when a patient is on-plan. Alerts are sent when patient deviates from the plan.

CO2 Heart Laser 2™

Bleck Design Group reduced size by 60% and weight by 1400 pounds - improved ergonomics, easy of use. Bleck Design Group developed the external skin design for PLC's high-power CO2 Heart Laser 2™. Bleck Design Group started with the previous clinical trial Heart Laser. The project compacted the technology resulting in a 60% size reduction and a weight savings of 1,400 pounds. Stability, doorway pass through and fluid spill proofing greatly influenced the design. The large handles and caster placement were designed to meet ergonomic needs of users transporting the device between operating rooms. The touch screen enables user-friendly operation.

The external panels are thermoformed ABS and the design won the Thermoforming Institute’s National Award for Innovation in Thermoformed Plastic Parts.

SuturTek 360° Fascia Closure Device

SuturTek is an award-winning medical device company that develops patented suturing devices for a wide range of applications. Bleck Design Group developed the drive mechanism and handle for this innovative fascia suturing device. The SutuTek 360 Facia Closure Device is a handheld mechanical suturing device that gives surgeons all the flexibility of suturing by hand, with improved control and speed, and no danger of needle sticks.

2006 Gold - Medical Design Excellence Award
2006 Silver - Industrial Design Excellence Award


Bleck Design Group developed the drive mechanism and handle for this innovative fascia suturing device


The project started with development of a feasibility model to demonstrate the concept. The model design and model fabrication were completed in about eight weeks.

Design Process

510K application and Feasibility Model: The project started with development of a feasibility model to demonstrate the concept and complete animal and cadaver tests. The model design and model fabrication were completed in about eight weeks and three models were sent for sterilization validation.

Surgical Evaluation: Under an Investigational Research Exception (IDE) the model was used in several human surgeries. The tests indicated increased length and changes in angles would be needed.

The design was revised to improve the ergonomics of the handle. The handle design was engineered to have a balanced feel with a minimum size. CNC machined prototype handles were used to meet the need for steam sterilization. These models were used to demonstrate the device for investors.

Production Design: The final design included one final set of ergonomic changes. The drive handle changed to have a reverse curve with a center groove to improve grip. Part designs were revised for injection molding and other high-volume production processes.

Dendritics 500 Gem Scale

Bleck Design Group invented the gem tray which uses a unique system of concentrianic steps to minimize cascading while pouring gems.

The Dendritics 500 is a portable carat scale to weigh 500 carats, 100 grams and 64.30dwt. all by .01 resolution. It is the ideal jeweler’s scale. At 8” x 7” x 2” and weighing less than 2 lbs. with batteries included, it is as portable as it is durable. The only jewelry scale ever designed with two displays to allow two parties to view the weight simultaneously.

Bleck Design Group invented the gem tray which uses a unique system of concentrianic steps to minimize cascading while pouring gems. The case is design with “coffee holes” to prevent spills from shorting out the electronics. We provide industrial design, mechanical engineering, and source management for molded parts.

In-Situ Spectroscopy Teact 4000

Working with Mettler Toledo’s core technology team, Bleck Design Group provided industrial design and engineering for the enclosure. Bleck Design Group created a compact enclosure designed to fit under laboratory fume hoods, occupy a minimum of bench space and provide chemical protection to the system. Working with Mettler Toledo’s core technology team, Bleck Design Group provided industrial design and engineering for the enclosure. The base provides a ballast weight to counterbalance the sampling arm. The housings are thermoformed from chemical resistant ABS blend and painted for chemical resistance.

Emerge Interactive: Hand Held Beef Inspection Instrument

Bleck Design Group developed the ergonomics, industrial design and mechanical engineering of the enclosure.The device is used inside meat processing plants - it must be waterproof, withstand animal fats, cleaning chemical and steam washing.

This hand held device flashes a high energy LED filtered light and can detect the presence of clorophile on animal carcases and displays this on the screen. The device is used inside meat processing plants. The device must be waterproof, withstand animal fats, cleaning chemical and steam washing. Bleck Design Group developed the ergonomics, industrial design and mechanical engineering of the enclosure.