The BioDesign Lab, led by Dr. David White, set out to develop a novel proof-of-concept device to address sleep apnea, a condition affecting millions globally. They wanted to transform an initial prototype—two CPAP devices mounted on plywood—into a polished, user-friendly product for medical trials, ensuring it could make a real difference for patients.

Globex partnered with the BioDesign Lab to redesign their sleep apnea prototype into a sleek, functional device for medical trials. The team repackaged the complex internals, including air-path systems and electronics, into a refined industrial design with an intuitive user interface, focusing on rapid manufacturing techniques to meet the limited budget.

To achieve this, Globex used SLS prototyping for internal components and PU casting for cosmetic parts, producing a small batch of 20 units. Working with local and offshore suppliers, they assembled and fine-tuned the devices in-house, ensuring they were both beautiful and fully functional for the trials.

Capabilities Used

• Requirements analysis and concept development

• 3D modelling / CAD design

• Industrial design and prototyping

• SLS prototyping and PU casting

• Assembly design

• Vendor management

• Boutique manufacturing

Globex successfully delivered 20 sleep apnea devices to the BioDesign Lab, meeting all design and budget requirements. Through this effort, the polished devices with their intuitive interface and functional design now stand ready for medical trials, supporting the lab’s mission to address sleep apnea.