R200 Platform
Design Background
The Leprechaun device was developed as an upgraded version of the Nanoview Biosciences R200. After the acquisition of Nanoview Biosciences by Unchained Labs, we shifted our focus to sizing down to smaller particles (35nm - 200nm) and capturing both lentivirus and exosomes. Leveraging the main optics platform from the R200, we upgraded our objective, electronics, stages, and shell on the hardware side.
Design Concept
Upgrading our objective from a 40x to a 50x magnification allowed us to increase approximately 2x contrast for our interferometric readings. This allowed us to bring our minimum detectable size limit from 50nm to 35nm, allowing us to better characterize Lentivirus. We developed new hardware requirements around the new objective to guarantee that all instruments would perform similarly. We simplified our electronics chain to improve manufacturing and hardware control times by eliminating an electronics board and having all communications driven by the main PCB. We upgraded our stage travel to allow the consumable to travel further out of the device, improving the user experience during scanning. The outer shell was rebranded to fit the Unchained Labs product portfolio look and feel.
New Sizing Profile with Hardware Improvements
Finished Product
Design Transfer
During the design transfer process, we tried to make the calibration and qualification of the instrument as automated as possible. Working with the manufacturing team in California, we identified some pain points during the process that could be improved. We developed software tech tools that automated 90% of the calibration and qualification, requiring the technician to view results and make adjustments as needed. This increased throughput by 3x, enabling our manufacturing team to meet product demand of shipping 15 instruments a quarter.