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CASE STUDY


HOW THE RISE EMERGENCY VENTILATOR WAS BUILT FROM SCRATCH IN 21 DAYS IN ONSHAPE

Meter’s remote engineering team relied on real-time CAD collaboration tools to
rapidly accelerate production


THE CHALLENGE

In the earliest days of the COVID-19 pandemic, U.S. government officials asked
hardware startup Meter to design an affordable and scalable hospital-grade
ventilator to address anticipated nationwide shortages. To avoid undermining the
already-strained supply chain, the design needed to be created with other
readily available machine parts not earmarked for specialized medical use. In
addition, Meter’s engineering team was forced to work from home by the
pandemic’s shelter-in-place mandates.


RESULTS

 * The Rise Emergency Ventilator was designed and manufactured in 21 days, a
   development cycle that typically would require many months.
 * Ventilator was produced for under $1,000, compared to the industry average of
   $25,000 to $50,000 per unit.
 * Engineering team went through six design iterations in three weeks,
   equivalent to producing a new improved ventilator every 3.5 days.
 * Onshape’s cloud-native product development platform enabled Meter’s extended
   design team of 50 people to collaborate remotely.

Download Case Study
Eduardo TorrealbaCo-founder & CEOMeter


> “Onshape was just incredibly valuable for us. We were moving way too fast to
> deal with emailing files around or setting up servers and a lot of the other
> things that we would need to do to have that same level of collaboration if we
> had been using other CAD packages."

IN LATE MARCH 2020, WHEN MEDICAL EXPERTS WERE PROJECTING MASSIVE SHORTAGES OF
VENTILATORS NEEDED FOR COVID-19 PATIENTS (AND SOME WORST-CASE-SCENARIO PLANS
CALLED FOR SPLITTERS TO PUT MULTIPLE PATIENTS ON THE SAME VENTILATOR), U.S.
GOVERNMENT OFFICIALS APPROACHED THE BOSTON‑AREA HARDWARE STARTUP METER FOR HELP.

Although the startup company was in stealth mode, it took on the challenge of
designing a more affordable ventilator that could be rapidly manufactured in
high quantities without relying on specialized parts already in high demand for
existing ventilators. According to The Washington Post, the price for
traditional hospital ventilators can range from $25,000 to $50,000 per unit.

On March 28, Meter pressed the pause button on their company and pivoted their
entire team to build the Rise Emergency Ventilator. One of their engineers had
previous experience researching manual bag resuscitator controls – the way to
accurately monitor airflow going from the bag to the patient’s lungs – at
Massachusetts General Hospital, and other team members had deep backgrounds in
manufacturing other hardware products at scale.

One of the team’s major focuses was improving the ventilator’s monitor and alarm
systems, allowing medical staff to remotely monitor multiple patients at once
through web dashboards and text alerts.

But the Meter team’s unique expertise and experience couldn’t prepare them for a
most formidable roadblock. All of the engineers were forced to work at home by
the pandemic’s shelter-in-place mandates.

REAL-TIME CAD COLLABORATION WAS CRITICAL FOR SUCCESS

Distributed product development teams work faster with Onshape’s real-time
collaboration tools. Multiple engineers can work on the same part or assembly
online and provide instant feedback to their colleagues.



Including Meter’s core team of a dozen engineers, about 50 people were involved
in the development of the Rise Emergency Ventilator. The extended team included
3D-printing experts, hospital clinicians, software developers and sheet metal
fabricators. There was no lengthy hiring process. The team rapidly expanded by
recruiting friends and colleagues from their personal networks.

“In many ways, our development process followed the same approach we usually
take, but we had to compress it into hours instead of days and days instead of
months,” recalls Eduardo Torrealba, the co-founder and CEO of Meter. “The
biggest way we did this was by ramping up the frequency of communication.
Individual contributors had multiple daily check-ins on Slack and video chats so
we were constantly raising questions, spotting problems and solving them.”

“In the first seven days, we had already done two revisions of the mechanical
design and started 3D prints of the first parts over the weekend,” he adds. “I
also went a little bit old school and was doing 50 to 60 phone calls a day
during this effort. Sometimes you just can’t beat a normal voice call when you
need immediate feedback.”

For engineering team members stuck in their individual homes, PTC’s cloud-native
Onshape product development platform, which enables multiple people to
simultaneously work together on the same CAD model online, was essential for
collaboration. Colleagues using Onshape can instantly provide feedback on each
other’s work as easily as making a comment in Google Docs or on social media.

“The fact that the tool was always live was really important for us. We had
several design reviews over Zoom with 8 or 10 people and somebody would share
their screen as they manipulated the model,” says Torrealba. “If someone had a
question they didn't just have to say, ‘Okay. Turn it around. Spin it. Do this.
Do that.’ They could be in the workspace with the designer and highlight things
and make edits in a much more collaborative way than I've seen with any other
CAD platform.”

For sharing designs with external partners, such as the sheet metal fabrication
experts at Prototek, the Rise team relied on Onshape’s Sharing feature, which
allows teams to grant instant access to collaborators with varying levels of
permissions. Partners can view, edit or comment on designs in a web browser with
no need to download or install special software.

“Onshape was just incredibly valuable for us,” Torrealba adds. “We were moving
way too fast to deal with emailing files around or setting up servers and a lot
of the other things that we would need to do to have that same level of
collaboration if we had been using other CAD packages.”

VERSION CONTROL: 6 DESIGN ITERATIONS IN 3 WEEKS

Product development teams using Onshape’s SaaS design platform benefit from
built-in version control without the need for an external PDM system.



The Rise Emergency Ventilator went through six design iterations in three weeks
– the equivalent of introducing a new improved version every 3.5 days. With
Onshape’s real-time data management, everyone on the design team can see changes
as they happen. A comprehensive Edit History tracks who made what change and
when, allowing teams to instantly revert back to any prior state of the design
if desired.

Torrealba says that Onshape gave the Rise team confidence that they were always
working on the latest version of their design, significantly reducing the
likelihood of manufacturing errors.

“We never had any designs released to a manufacturer that were the wrong
revision,” he recalls. “That’s huge. At every single step of the prototyping
stage, all the parts matched up and were the right version. I think about the
old world of CAD where you end up exporting zipped files and all this crazy
stuff. You send the wrong thing, and half your parts don't fit.”

“I've had that happen with almost every product that I've ever built. So this is
a first for us. It was great to see Onshape help us deliver such a streamlined
design,” adds Torrealba.

CREATING A MORE RESILIENT SUPPLY CHAIN

The Rise Emergency Ventilator does not require the same specialized replacement
parts currently in high demand by hospitals and other healthcare facilities.



One of the most important objectives of the Rise Emergency Ventilator project
was to not undermine existing medical supply chains, already under heavy strain
from different U.S. states competing for the same resources. Consequently, the
design was created with other readily available components not earmarked for
specialized medical use.

The goal was to enable any factory that can make consumer appliances to be able
to quickly build tens of thousands of ventilators on demand.

In the early days of prototyping, the Rise team relied on 3D metal printing at
Desktop Metal to make standard off-the-shelf parts that were not immediately
available because of supply chain problems.

“We actually printed parts that we also ordered from suppliers, but we knew that
we were going to get them off the metal 3D printer 24 or 48 hours faster because
of the disruption in the logistics networks,” Torrealba says.

“Normally, I would never go through that much trouble to save 24 or 48 hours,
but with the speed that we were moving at, it was a huge deal. Because of COVID,
we had multiple delayed items we ordered from very dependable suppliers that we
work with all of the time. They would say they were delivering tomorrow and then
they’d say that for the next three days in a row. Having the dependability of
metal 3D printing was incredibly important for us during our prototyping
stages,” he adds.

Supply chain issues aside, a teamwide willingness to sacrifice sleep was also
critical for success.

“By the end of this, most of us had worked three consecutive 120-hour weeks,
which just isn’t sustainable for very long,” Torrealba notes. “But in a time of
a crisis, if that needs to happen, it was gratifying to see our team step up and
do that.”

The Rise Emergency Ventilator was developed in partnership with a coalition of
healthcare and technology partners, including PTC, Desktop Metal, CANCAN,
Rigado, Formlabs, Prototek, FATHOM, Tulip, Precision Graphics, and CircuitHub.


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