Visual Inspection Roller
Design and Cost Efficiency at Lyra Therapeutics
I was solely responsible for the design, creation, and implementation of this tool at Lyra Therapeutics. This tool removes the need for operator contact during visual inspection processes. The enclosed gearbox allows both steel rollers to spin the same way, allowing for a quick and easy visual inspection of the cylindrical product. The tool fits beneath the microscope and once the microscope is focused on one unit, it never needs to be refocused. The tool is made of Stainless Steel rollers, PLA housing, PTFE bushings, and acetal plastic gears.
To meet expectations, this tool needed to be able to rotate 360 degrees for a clear view of the cylindrical product during inspection. When doing initial CAD for a project like this, I based the design off of my knowledge of hotdog rollers. If two cylinders turn the same way, then the product on top should spin the other way with the same velocity as the outside of the cylinders. To decrease the effort required and cost of production, the rollers are much smaller than those you might find in a hotdog cooker. Next, I designed a simple gearbox and integrated cleanroom-safe McMaster gears and bushings. From here, I 3D-printed my first prototype. Once the prototype proved operational, I created an engineering drawing and ordered metal rollers.
The final design incorporates steel rollers that will be able to be sterilized in a cleanroom with IPA wipes. In future production, simplicity and minimal human input is desired since different operators may have slightly different standards for what an acceptable particulate size is. The roller also allows for the microscope to remain at a constant height, and every inspection should be immediately in focus and superior to those performed by operators holding the product in focus with their hands. This tool is a step towards automation since a standard microscope height would be preferred in a validated production process. The roller is currently in R&D use and will be introduced into commercial production with the 2024 move to a larger manufacturing space. See the finished visual inspection roller below!
