Innovative thermoformed enclosure supports groundbreaking medtech

Award-winning DFM and pressure forming replace injection molding

Overcoming the challenges in developing new medical devices can be a rewarding experience for everyone involved in the product design project. Helping to develop a non-invasive cancer treatment system can also help save lives.

A medical OEM needed a highly cosmetic enclosure for their new equipment, plus several plastic internal parts. The product design team approached Profile Plastics to thermoform these components. The lower production volume of such specialized equipment ruled out other processes, like injection molding, which require expensive tooling.

Project background

The OEM developed a non-radiation-based cancer therapy system that uses targeted ultrasound waves to destroy tumors without harming the surrounding healthy tissue. Similar to ultrasound kidney stone treatment, the method uses water to amplify and focus the sound waves.

The new system was packaged into two carts. One held the electronics. The second cart supported the fluidics, filtering air out of the water, so it doesn’t interfere with the ultrasound. After the water is used, it’s returned to a waste basin in the cart for disposal.

Each cart needed removeable enclosure panels along with bins and covers. The design team partnered with Profile to finalize the design and manufacture of all 10 components. Leveraging their capabilities completed the individual pieces on time, on budget.

Challenge: Balancing airflow, patient safety, and aesthetics

The design of the enclosure was almost 90% complete when the customer approached Profile. However, several elements required design assistance.

Profile’s DFM (Design for Manufacturing) services primarily focus on adapting an existing design to thermoforming processes. In this case, several key aspects of the designs needed some adjustment. Each change also needed to control manufacturing costs.

The customer’s overall aesthetic requirements needed to be maintained while providing adequate airflow to cool the internal electronics and mechanical components. Addressing patient safety was also a concern.

Solution: Enhancements that improve design

Profile recommended using KYDEX® T brand PVC/Acrylic blend material for the enclosure panels, because of its superior chemical resistance and UL 94 V-0 flame rating. This thermoplastic is also available in custom color which eliminates the need for painting the molded parts. Interior utility components were vacuum formed using PETG.

Each cart was enclosed with six panels. Pressure forming techniques provide superior surface aesthetics. Formed on aluminum tooling with an acid etched texture, this affords an attractive yet cleanable surface on the outside of each final part.

Profile’s solution offered tight-fitting alignment between panels. The engineering team created a hidden fastening system for a clean transition between parts. This also made it easier to remove panels in the field for maintenance.

Two hidden magnetic attachments points were also added to the device. These conveniently hold tools for technicians during use.

The most visible and critical enhancement was the venting. It needed to provide adequate airflow while providing patient safety, preventing fingers from being inserted. Profile created a unique, intricate vent pattern on a curved surface that met both goals. It also maintained a family resemblance to previous vent designs, supporting the overall design aesthetics.

To facilitate production, the design was optimized for proper draft and spacing. This limited the depth of material draw and made demolding easier. Each vent was formed-in then CNC machined from the back, resulting in a clean, more consistent front surface.

Results: Improved performance while reducing costs

Fully Assembled Cancer Treatment System Cart

Profile’s design and production teams exceeded all the OEM’s goals on the project while achieving target price points. Pressure forming delivered superior outer enclosure panels. The KYDEX® T material with molded-in color resulted in attractive, lightweight, rigid parts.

Vacuum forming was used to produce extremely cost-effective utility components, including the water and waste basins. Supporting the weight of the water was key to success for these parts.

The fluidics cart project displayed how multipart thermoforming innovation supports medical advancement. In recognition of this, the cart received two awards at the Society of Plastics Engineers (SPE) Thermoforming Division’s 2025 biennial conference. 

Conference attendees voted it the best overall new part shown, giving it the People’s Choice award. Competition judges also awarded it Silver in the pressure forming category. Profile now holds 43 parts awards from the SPE Thermoforming Division since the 1980s.