Medical Product Design: Mechanical Engineering

Mechanical engineering is a core competency at KMC Systems. The medical devices we design typically require complex mechanical assemblies to automate medical testing or parts handling. The objective of our mechanical design process is to create cost-effective, producible, and reliable products. We design with assembly, testability, and serviceability in mind.

To conceptualize and optimize designs for form and fit, we are well-versed in a variety of CAD systems and analysis tools. We’ll present you with several system- and subsystem-level design concepts before we proceed with the final concept. The mechanical engineers work in a product data management environment (PDM) to ensure integrity of the CAD data. We also use finite element analysis (FEA) systems to analyze parts and assemblies. This creates a more efficient development cycle and ensures more reliable and robust products.

The mechanical engineering group is also responsible for designing the chassis, cover system, and packaging. We have expertise in the following areas:

  • packaging electronics
  • sensors
  • power supplies
  • and power distribution centers

We are also skilled at designing a range of user interfaces, including disposables, access doors, displays, keypads, indicators, and alarms.

Whether there is a requirement to move fluids, cuvettes or test tubes, using linear or rotary handling mechanisms, we have mechanical engineers on staff with relevant expertise, including strengths in: 

Medical Device Ideation

Medical device ideation is a core competency of KMC Systems. And we meet the needs and expectations of our customers.

The mechanical engineering department is made up of a unique cross section of mechanical engineers that are both cutting-edge and experienced. The diverse backgrounds create unique, cost-effective concepts for our customers.

Robotics, Automation and Motion Control

Robotics, automation and motion control are core competencies at KMC Systems.

Our mechanical engineers have experience with a number of motor drive technologies, including micro-stepping drives, DC brushless motors, and servo-motors. KMC has invested in developing our own “off-the-shelf” hardware and complimentary software solutions for commonly used motor drive technologies. We’ll also identify the ideal mechanism solution for your device.

Ultimately, we’ll select the ideal components and techniques to ensure your device functions.

Top of Page

Fluidics Management

KMC Systems has a history of developing fluid-handling systems. Our engineers work closely with customers to develop instruments that meet required delivery characteristics (such as accuracy and precision specifications and carryover limits). We have designed a number of systems to move aqueous fluids and have experience with gas-based pumps and pneumatic systems.

Our expertise in fluidics ranges across a wide variety of industries. We have designed pipetting robots, high-precision displacement pumps as well as re-agent metering, bulk fluid delivery and waste recovery systems. KMC Systems also applies innovation and experience to meet difficult design challenges and stringent requirements for sample and reagent delivery, sample carryover, throughput, mixing, size and weight.

Accelerating development. minimizing costs. That’s what KMC does.

Top of Page

Machine Design and Analysis

Machine design is the process of turning a series of elements (such as bearings, belts, pulleys, shafts, motors, etc.) into a system that works together.

This process of turning these concepts into machine elements is a core competency. Our mechanical engineers rely on decades of experience with a wide range of machine elements. At KMC Systems, engineering principles and lab experience go hand-in-hand with tools such as MathCad and Ansys to analyze and solve design problems. This approach enables unique solutions for our customers and inspires confidence in the results we produce.

Top of Page

Structural and Thermal Analysis

Many medical devices and instruments must withstand extreme usage conditions, such as high and low temperatures and load capacity. Our mechanical engineering group applies industry-accepted structural and thermal analysis techniques to ensure device performance.

Our structural and thermal analysis process allows us to bring customers robust designs created within an accelerated design cycle. We use powerful modeling tools (such as SolidWorks, and Pro/ENGINEER), coupled with analysis tools (such as Pro/MECHANICA, Cosmos and Ansys) to avoid the cost and time associated with iterative prototyping. At KMC Systems, quantifiable optimization is completed within hours instead of weeks, and initial prototypes often require only minor design revisions to become producible.

Efficiency is our core objective, and we select components that are optimized for both cost and performance. Our engineering staff has many years of experience with precision temperature calibration, material science and temperature-control systems.

Thermal control is another skill of our group. We use custom temperature-control modeling software to fine-tune each system. Whether your instrument requires low- or wide-range temperature-control systems, we can apply the ideal technology to optimize its function.

Top of Page


Our mechanical engineering team specializes in state-of-the-art diagnostic systems that often require analysis of complex chemistry reaction. Electro-optics are a common approach for these detection technologies.

We have experience with a wide-range of electro-optic technologies, including

  • phototransistors
  • photomultiplier tubes
  • CCD arrays
  • digital cameras
  • lasers and others.

We have designed precision optics and electronics to meet challenging optical requirements at many different wavelengths, ranging from luminometers with extreme sensitivity to low-cost fluorometers.

KMC Systems also developed software with image processing and object recognition functions for use with these electro-optic assemblies.

Our electro-optics capabilities are further supported by our parent company, Elbit Systems, which develops, manufactures and integrates advanced, high-performance defense electronic and electro-optic systems for customers worldwide.

Top of Page