DFMA Case Study: Ciba Corning Blood-Gas Analyzer

Overview

Ciba Corning set aggressive targets to modernize its blood-gas analyzer family around a common base platform that could be upgraded in the field. The goals: lower cost, higher quality, durable construction, faster assembly, and easier use.

DFMA Approach

The engineering team paired design and manufacturing engineers from the start and ran all assemblies through DFMA® analysis. That work produced assembly cost estimates and—more importantly—structured conversations about material choices, consolidation opportunities, and part fit/locating features.

Key Design Moves

• Caseworks simplified: Two outer shells hinge together like a suitcase, improving fit and speeding assembly.
• Hydraulics consolidation: The reagent manifold was redesigned as a single acrylic block, removing numerous tubes and fittings.
• Self-locating parts: Pins and dedicated features align components without re-orienting, reducing handling time and error risk.
• Fastening strategy: Balanced use of molded snap-fits and screw bosses/Tinnerman-style solutions to cut hardware and minutes.

Results

• ~48% reduction in total parts count.
• ~60% fewer fluidic connections.
• ~22% lower overall cost.

Prototyping & Validation

Solid modeling and rapid prototyping (including stereolithography, cast urethane, and structural foam) supported the higher functional density created by DFMA-driven part consolidation, enabling quick iteration and fit checks.

Team Perspective

Design and manufacturing worked side-by-side throughout, using DFMA to quantify assembly effort and guide decisions. The focus on self-alignment and single-orientation assembly eliminated wasted motion and made the final build faster and more robust.

What This Means for You

• Use DFMA early to expose simplification opportunities and quantify the impact.
• Co-locate design and manufacturing decisions to close the loop on part fit, features, and fastening.
• Leverage rapid prototyping to validate higher functional density after part consolidation.

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