Radiotherapy Headrest for Patient Positioning: Full Product Development and Procurement

Overview

Led the full product development of a $20,000 medical headrest project for patient positioning during radiotherapy, taking responsibility for the project from initial concept through prototyping, supplier coordination, manufacturing, and quality control. I designed four new product lines to accommodate different patient positioning and immobilization requirements: extended plastic headrests for water-activated polyurethane immobilization systems, standard plastic headrests for thermoplastic applications, foam versions of the standard headrests for increased patient comfort, and extended foam headrests. Leveraging CAD and design skills developed through UBC AeroDesign, I designed complex, organic geometries that conform to a range of patient head anatomies while considering manufacturability, ergonomics, and integration with existing immobilization systems. I developed and evaluated multiple CAD iterations through rapid prototyping and physical testing, using prototypes to identify design issues and refine geometry, fit, and functionality before moving toward production. Beyond product design, I was responsible for the manufacturing and supplier development side of the project. I worked directly with manufacturers to source components, evaluate quotations, understand manufacturing capabilities, and select appropriate processes, with a primary focus on PETG thermoplastic vacuum forming and polyurethane molding. I also researched and applied relevant ISO standards and medical-device manufacturing considerations to ensure the products and manufacturing processes were appropriate for the medical industry. I also developed and implemented a quality-control process for incoming prototypes and production shipments, establishing inspection criteria and procedures to verify dimensional accuracy, material quality, surface finish, and overall product conformity. This project provided end-to-end experience in medical product development, combining mechanical design, prototyping, manufacturing, supplier management, quality assurance, and regulatory considerations.

Key Deliverables

• 4 New Medical Headrest Product Lines - Designed extended and standard plastic headrests, along with corresponding foam variants for radiotherapy patient positioning and immobilization.
• End-to-End Product Development - Managed the project from initial CAD concepts through iterative prototyping, physical testing, supplier procurement, and production readiness.
• Manufacturing & Supplier Development - Worked directly with manufacturers to evaluate quotations, materials, and manufacturing processes including PETG vacuum forming and polyurethane molding.
• Quality Control System - Developed and implemented incoming inspection procedures for prototypes and production shipments, including dimensional, material, and visual quality checks.