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Digital PCR – a technology set to transform clinical testing?

Pregnancy screening, cancer treatment, organ transplant – digital PCR testing has the power to enhance clinical decision-making. But what is needed to take it mainstream?

Polymerase Chain Reaction (PCR) testing has reached unlikely levels of fame due to the COVID-19 pandemic. However, its latest evolution, digital PCR, could be a real game-changer for commercial diagnostics.

The power of digital PCR

When people talk about PCR testing, they often refer to quantitative PCR. This technology is fantastic at delivering binary answers, for example, whether a disease is present or not. It can also determine to some extent how much of a disease is present in a sample (though the process is inaccurate). Quantitative PCR’s quantification can be improved by calibrators, but this is complex, expensive, and time-consuming for a lab to perform.

Digital PCR advances this technology to deliver precise quantification and improves detection of low-frequency DNA targets.

The potential to transform clinical decision-making

The key benefit of digital PCR can be summed up in two words: better data. It has the power to transform clinical decision-making, for example, in the following areas:

Pregnancy screening

Highly accurate testing for chromosomal trisomies, such as Down’s syndrome, by detecting traces of foetal DNA in maternal blood. Next-generation sequencing (NGS) is an existing alternative but has extremely complex protocols, including DNA purification, DNA library preparation, sequencing, data alignment, and analysis.

Cancer treatment

Pinpointing disease progression by detecting tumor DNA in liquid biopsies.

Organ transplants

Detecting DNA sequences leaking from a donor organ (a sign that the host immune system is rejecting it).

Virus detection

Increasing accuracy in treatment of HIV, hepatitis C, herpes, cytomegalovirus, and other infections.

Disease diagnostics

Quantification of bacterial species in stools due to digital PCR’s lower sensitivity to inhibitors.

Digital PCR could also deliver accurate quantification of levels of other infectious diseases such as respiratory viruses and sexually transmitted infections. This precision isn’t currently available but could be useful for clinicians to differentiate between different stages of infection.

How does digital PCR differ from quantitative PCR?

Digital PCR is a development of ‘standard’ PCR, using the same concept of exponential amplification of template DNA with DNA primers and a polymerase enzyme. It has two crucial differences: compartmentalization and end-point data collection.

Compartmentalization

Instead of performing a reaction on a whole sample, digital PCR splits the sample across a large number of separate compartments. ‘Compartment’ could mean a microfluidics chip, or a droplet suspended in an emulsion.

Each reaction is capable of detecting a single molecule of DNA. A larger number of amplification cycles are generally run, typically 60 versus 40 for standard PCR. Just one DNA molecule in a compartment is enough to initiate a PCR amplification reaction.

End-point data collection

Unlike quantitative PCR which reads after every amplification cycle, digital PCR just needs to read once when all the amplification cycles are complete. This is an important saving, as otherwise, all the thousands of individual compartments would need to be read every cycle, which would be a significant challenge.

Digital PCR overview

What’s stopping the mass adoption of digital PCR?

Though digital PCR has been around for 20 years and is mentioned in thousands of patents, only a handful of commercial products use the technology. The primary challenge innovators need to crack for it to go mainstream is optimal compartmentalization.

Cracking compartmentalization

Compartmentalization affects key performance parameters, such as the assay’s dynamic range, linearity, accuracy and ease of use; its cost; whether it’s run as a batch or on-demand; and how many samples can be run at once. The number of compartments in the assay must be high, relative to the concentration of input DNA molecules in the sample. But if the assay uses too few compartments, the accuracy of quantification will be too low, and the assay must be repeated using a diluted sample.

Why does compartment design matter?

Digital PCR’s randomly apportioned target molecules across a large number of compartments mean there will be some compartments with no targets, some with one, and a few with two or more. As it’s not known how many target molecules are in each positive compartment, the Poisson distribution is used to determine the most likely proportions of compartments with one, two, three, or more DNA targets. Using the Poisson distribution allows accurate quantification, but relies on two important factors:

  1. The input template being randomly spread throughout all the reaction chambers
  2. All compartments being the same size

These are critical parameters, and there are two main ways to achieve them. The first is passing the sample over a microfluidic flow cell containing microwells commonly filled using capillary action. The second is encapsulating the nucleic acid in a huge number of water droplets in an emulsion of oil, with each droplet containing a separate reaction.

Microfluidic droplet generator developed at CDP

The ideal compartmentalization system would retain the ease of use of current quantitative PCR systems and have a similar lab-bench footprint and costs. However, current approaches (typically involving microfluidics or droplets), require multiple complex disposables and sophisticated optics. If a new approach was developed with lower costs, clinicians and test centers may well convert to digital PCR for all their applications. The company that manages to crack this challenge has the potential to dominate the PCR market and provide huge advances to clinical decision making.

To talk to us about our current innovation in the field of digital PCR, get in touch.

How to boil your egg perfectly every time

How to boil your egg perfectly every time – according to simulation

Search ‘how to boil an egg’ on Google, and you get over three billion results, some telling you to put the egg in cold water after boiling to preserve the runny yolk. Intrigued, we decided to investigate the science behind this advice.

Rather than heading straight to our lab for experimentation, we used computer simulation to calculate and model the movement of heat and temperature through the egg and surrounding fluid. Simulation lets us predict data at times that would be impractical or expensive in actual experiments.

Modeling the heat flow in a boiling egg could be a surprisingly tricky problem. An egg consists of a solid shell holding the white and yolk, initially in a liquid state but solidifying as the cooking continues. Being natural products, the exact properties and sizes of eggs vary.

To simplify the problem, we found technical publications that describe the average dimensions and thermal properties of the shell, white, and yolk for a typical egg. We decided to define these properties at a temperature of 60°C, which is around the point the yolk starts to solidify. Using computer-aided-design software, we created the geometry of the egg, and defined a body of fluid to surround it. This fluid body represents the boiling water in a saucepan during the first cooking stage. Afterward, the fluid body can be used to mimic cool-down in air or a bowl of 10°C cold water. We decided that the eggs would start the process from room temperature in all cases.

We ran the simulation using powerful software, Ansys Fluent. The software was initially developed for understanding problems such as the flow of air over planes or heat in a chemical plant, but it can be applied to domestic problems such as the humble boiled egg. To allow the simulation to run quickly on an ordinary computer, we took advantage of the fact an egg shape is a body-of-revolution and looks the same however it’s rotated around its axis. This lets us model it as an axisymmetric body that the computer considers two-dimensional. This reduces the number of calculations and gives us the answer quicker and more cheaply than simulating the real-life, three-dimensional shape.

As an example of the simulation results, Figure 1 shows the temperature distribution on a slice along the egg’s axis after cooking in boiling water for six minutes. The material towards the outside has heated up close to the temperature of the water. However, the central region corresponding to the yolk is still around 50°C, corresponding to a runny egg.

Figure 1: Temperature distribution on a slice across the egg after six minutes of immersion in boiling water.

Figure 2 shows a side-by-side comparison of subsequently cooling the egg in air or 10°C water for five minutes (five minutes being our estimate of the time it takes to finish eating our first dippy egg and move on to the second). When cooled in air, the central region of the egg continues to increase to 70°C, removing the prospect of a runny egg, even though the outer region and shell have decreased in temperature. In contrast, after cooling in water, the central region stays unchanged at 50°C while the shell has decreased close to 10°C. Leaving your perfect dippy egg in air risks ruining the runny yolk – but cooling it in water may save it.

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Figure 2: Temperature distribution on a slice through the egg following cooking
and five minutes of cooling in (a) air and (b) water.

As well as modeling the overall temperature in the egg, we extracted the data for two specific points – at the center and the edge of the egg – and plotted them on a graph (Figure 3) to see how they differed. The data showed that the yolk’s temperature lags that at the shell. This is because the thermal diffusivity of the white and yolk are relatively low. Thermal diffusivity is a measure of how quickly heat can move through a material. So, it takes a while for the yolk to heat up, but once it does, it keeps cooking, absorbing heat from the rest of the egg material. It’s slow to respond to changes in the surrounding water (or air). The temperature just inside the shell responds much more quickly to changes, though, since the path the heat needs to travel from the surrounding fluid is considerably shorter, and the thermal diffusivity of the shell markedly higher.

How to boil your egg perfectly every time|||||||
Figure 3: Temperature profiles with time at the center point of the yolk (circles) and adjacent to the shell (crosses)

With the aid of some considered simplifications, we think this simulation analysis has proven the cookery expert right: cooling eggs down in cold water really does preserve the runny yolk. However, whenever you analyze a problem for the first time, it’s important to compare results against an experimental benchmark, so you can confirm the realism of the assumptions and simplifications in a computer simulation. We took three eggs and boiled each for six minutes in a lab beaker. One was opened straight away, and the other two after cooling in cold water or in air for five minutes. As predicted by our computer simulation, the yolks ranged from runny to fully cooked. And the best thing about this experiment? Everyone got an egg cooked precisely to their liking at the end.

 

Connect with CDP

Contact us to find out more about our capabilities and how we use science to understand and improve everyday products.

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Reducing the carbon footprint and plastic waste of LFTs: Evidence-based opportunities

Billions of lateral flow tests have been used worldwide during the COVID-19 pandemic – over two billion have been provided in the UK alone. Debate has raged on social media about why the tests need to use so much single-use plastic and how they could be made more ‘sustainable’. The test strip caseworks is a particular source of dismay – why so much plastic to house such a tiny test strip?

With the UK government ending the free distribution of lateral flow tests for the general public – citing a transition from emergency response to longer-term management of the pandemic – now is the ideal time to look more closely at the sustainability of these lateral flow tests, and to seek the data to demystify some of the emotional assumptions being made.

Familiarity with lateral flow testing has certainly increased, as has confidence in their clinical performance. It’s expected that lateral flow devices will be more present in our daily lives post-pandemic – not just for COVID-19 and pregnancy testing but to diagnose diseases such as seasonal influenza and sexually transmitted infections – all from the comfort of the home.

We’ve carried out a high-level assessment to quantify the approximate environmental impact of lateral flow tests and identify evidence-based suggestions for improving their environmental sustainability.

Why do COVID-19 lateral flow tests contain lots of single-use plastic in the first place?

The emergence of COVID-19 was a global emergency, and vast quantities of lateral flow tests were needed urgently. Once developers could produce the right immunoassay chemistry to detect the virus (SARS-CoV-2), it required implementation in a low-cost, low-risk device, that has a mature supply chain – with proven, readily available materials that wouldn’t compromise analytical or clinical performance.

This meant using existing plastic casework designs to retain and protect the nitrocellulose test strip. Plastic is robust, low cost, lightweight, easy to transport, and easily printed for QR codes and LOT numbers. Critically, it’s a consistent material proven for the highest volume manufacturing and won’t interfere with the immunoassay chemistry.

From a performance, cost, and manufacturing perspective, redesigning the product with new materials would have been high risk. Material changes may also have needed significant R&D costs, new capital equipment as well as additional cost and effort needed to demonstrate equivalence and achieve regulatory approval – risking the ability to provide sufficient numbers of high-quality tests, at speed during the pandemic.

Our results: The sustainability of lateral flow tests

But how serious an environmental impact do these tests have? To find out, we broke down a test into its constituent components and weighed them to calculate the approximate environmental impact, using standard emissions factors to calculate the carbon footprint of a single test.

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We focused on carbon footprint (the carbon dioxide and other greenhouse gases emitted during manufacture, transport, and disposal of the tests) and plastic waste (waste that would persist indefinitely if released into the environment) – the two issues that have attracted the most attention around lateral flow tests. A more comprehensive study should consider a broader range of environmental impacts, for example, the use of scarce resources and emission of other pollutants to avoid unintended consequences of any product changes.

Our results reveal:

  • The components needed to conduct the test account for around half of the carbon footprint and around two-thirds of the plastic waste. Packaging makes up most of the rest – as is often the case, a surprisingly high proportion of the total environmental impact
  • The test strip caseworks, which attracts the most comment online, is responsible for around 30% of the carbon footprint and 40% of the plastic waste. While it’s the most significant single contributor to the environmental impacts we evaluated, the large number of other small parts is also significant. Focusing on the caseworks therefore might not be the best strategy for improving the sustainability of the tests overall.
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Lateral flow tests a minor piece of UK healthcare’s environmental impact

To put these numbers into context, we can compare the environmental impact of the two billion COVID-19 lateral flow tests distributed in the UK with the UK healthcare system’s overall environmental impact. We estimate the UK’s lateral flow tests have a carbon footprint equivalent to around 0.5% of the total NHS carbon footprint. This isn’t a trivial amount, but it’s also not the largest single contributor to the impact of the UK health system.

It’s also worth considering the positive environmental impact of a user-administered test on the health system. Conducting a test at home can eliminate the need for an individual to visit a test site, GP’s surgery, or hospital (assuming the clinical performance of the lateral flow test is adequate). Based on estimates from the Sustainable Healthcare Coalition, one lateral flow test has around 5% of the carbon footprint of a single GP appointment and produces a similarly low percentage of non-degradable (plastic) waste.

And that’s before we consider travel. We estimate one lateral flow test has the same carbon footprint as driving 350 metres in an average UK car. So, if you’re driving yourself to a test site or GP surgery some distance away, at-home lateral flow tests compare even more favorably.

If a lateral flow test prevents an individual from transmitting COVID-19 to a vulnerable person, there’s a public health benefit – as well as an environmental benefit – to keeping people out of the hospital. We can all see the discarded waste from home tests, but the less visible impact from energy- and material-intensive medical interventions is often significantly higher.

These approximate figures demonstrate why building an evidence base is vital during product development targeting sustainability objectives – because the results can be unexpected and non-intuitive.

Quick ways to optimize today’s lateral flow tests

Just because waste from lateral flow tests might not be the most urgent sustainability issue for UK healthcare, that doesn’t mean we can’t and shouldn’t do something about it.

We used the ‘avoid/shift/improve’ model to find potential quick wins for lateral flow tests. These reduce the carbon footprint of each test by nearly a third and the plastic waste by almost a quarter – without impacting the fundamentals of how the test works.

They include:

  • Eliminate waste bags. There’s a case for quickly isolating contaminated waste (even given COVID-19 also spreads from infected individuals through the air), but the bags account for around 5% of the carbon footprint of the test. It’s not clear how widely used they are in a domestic setting – there may be a risk-based justification for not including them in the test kit.
  • Package all the test strips in a single foil pouch. Using a single re-sealable pouch to protect the tests from ambient humidity (rather than individually packing each test in a pouch with desiccant) is common in packs of lateral flow tests designed for use by healthcare professionals. However, once opened, the stability lifetime of the remaining tests is affected.
  • Reduce the size of paper instructions. These are important for the effectiveness of the tests and are a regulatory requirement, but account for 5% of the carbon footprint of a test – could they be reduced in size?
  • Eliminate the cardboard sleeve. This packaging isn’t essential to the safe and effective functioning of the test, and it seems likely that the functions it does provide could be achieved with less material.
  • Prefill the extraction tubes with buffer solution. This is already done in some test kits, although manufacturers need to be conscious of moisture loss and the effect on shelf life. However, the separate plastic vial used in the test kit we studied accounts for around 5% of the carbon footprint and plastic waste.
  • Increase the size of the pack from seven to ten tests. This would mean less package waste per individual test. Including ten tests in one pack instead of seven reduces the carbon footprint by around 5% (depending on how many other optimizations are done at the same time). Perhaps a pack of seven tests was originally designed to cover a week of daily testing – but is that how tests are being used in practice?
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Redesign of the test strip caseworks

Looking to the longer-term gets us into product redesign – creating a new generation of the product with sustainability in mind. Doing this can take significant investment since, for medical devices, it’s likely to require new regulatory approval, which is a lengthy and costly process.

A popular idea circulating for lateral flow tests is to minimize the plastic test strip caseworks (without compromising the essential functions of providing a stable platform, and protecting the nitrocellulose test strip). It might be possible to halve the caseworks mass and reduce the overall carbon footprint and plastic waste by 15-20%. This would require significant investment in R&D, production tooling, and regulatory approval hoops to jump through – but could be worthwhile if future demand for tests stays high.

Longer-term options

If we consider that the world may require billions more lateral flow tests over the coming decade, a more comprehensive redesign becomes commercially viable. This could involve stripping the design back to the fundamental requirements for a lateral flow test – flowing a sample through the test strip in a way that is controlled and free from contamination. Current designs take advantage of established components to collect, buffer, and dose the sample – but, at this production volume, it may be worthwhile designing a system from the ground up that is optimized for cost, usability, performance, and sustainability.

Sustainability as a brand differentiator

It’s clear there’s scope to optimize lateral flow tests to reduce their environmental impact – and a systematic analysis reveals options beyond those that might jump out to someone when they use the tests. But it’s essential to put the impact of lateral flow tests in the context of the wider healthcare system, to focus resources where they can have the most environmental impact – and to recognize that, sometimes, the plastic waste people can see helps to avoid more serious, but less visible consequences.

On the other hand, while visible plastic waste from lateral flow tests may not be the most pressing environmental issue facing the healthcare industry, it highlights the growing influence consumer opinion is likely to have as diagnosis and treatment shift from hospitals to homes. And as lateral flow tests become (in the UK, at least) a product people buy with their own money, choosing from a range of options, there may be a competitive advantage for businesses that take note and optimize their products for sustainability.

References
  • Prime Minister sets out plan for living with COVID [Internet]. GOV.UK. 2022 [cited 1 April 2022]. Available from: https://www.gov.uk/government/news/prime-minister-sets-out-plan-for-living-with-covid
  • The Sustainable Healthcare Coalition. Care Pathways Calculator. [Internet]. Sustainable Healthcare Coalition. 2022 [cited 1 April 2022]. Available from: https://shcoalition.org/

Connect with CDP

For more information on reducing the environmental impact of lateral flow tests without compromising performance, contact Cambridge Design Partnership.

Mastering fluid flow to enhance user experience|

Mastering fluid flow to enhance user experience

Ice cream and blood are two things you probably don’t want to think about simultaneously. But both are full of organic proteins and fats and behave differently from a fluid like water when they’re pumped through tubes. Innovators sometimes think about these similarities when creating, for example, a novel ice cream dispenser or device that filters out platelets from donor blood .

How a substance flows is a vitally important consideration for many products, from foods to skincare to medical devices to household paints. Development teams need to keep in mind a wide range of flow behaviors (for example, flow through nozzles, non-Newtonian flow, and foaming) to hit the sweet spot: a positive user experience that makes a product stand out in a crowded market. This means thinking about the science of how liquids and gases behave (fluid dynamics), as well as how the product responds to user interaction.

Look at how the squeezable plastic ketchup bottle differs from the glass bottles that were standard before 1983. The new design completely changed the user experience – no more digging down into the bottle with a knife to get the ketchup flowing again. Things became even easier for ketchup lovers with the debut of the upside-down squeezable bottle – no more awkwardly storing ‘regular’ bottles upside down in the fridge.

Or think about how the experience of washing your hands changed after the arrival of the liquid soap dispenser. Instead of having to share the same bar of soap with others, people can now wash “without the soapy mess”, as Robert R Taylor, who introduced SoftSoap liquid soap, put it, and can take only as much soap as they need.

While the flow of some liquids is analogous to water, whose behavior is well understood, other substances behave in much more complicated ways, requiring in-depth analysis work to understand when designing new products. For example, the air bubbles in ice cream make it behave as a liquid foam. Ice cream’s flow will change depending on how you’re dispensing it: Push it at high pressure through a narrow channel or nozzle, and the air bubbles will be compressed, allowing more ice cream to flow through the nozzle at once. When the ice cream is returned to normal pressure, the air bubbles re-expand, and the ice cream returns to its original size. Because of this complex and variable behavior, designing a product to dispense ice cream relies on hands-on experiments… which can mean going through gallons of ice cream before you can create a design that works as intended. Only by conducting these experiments to understand ice cream’s behavior can you build the mathematical model required to effectively develop a high-performance machine.

While it’s a shame to use gallons of ice cream in the quest for a better product, it’s not an environmental disaster. But shipping water-based products around the world does contribute to fossil fuel consumption and climate change. Removing water from laundry detergent helps cut shipping emissions by reducing bulk and making shipping more efficient. But it also dramatically changes how detergent flows and gets used by consumers. For example, measuring out 10 ml more detergent than recommended likely wouldn’t have an impact if you’re using a product that’s mostly water. But being off by 10 ml when detergent is concentrated could make a big difference for your laundry. So, it’s vital to ensure that dispensing is accurate, which requires an understanding of flow.

There are so many flow behaviors that can affect a product’s design. For example, should a container for insecticide include a mechanism to avoid skin contact and spillage? How could a medical device for freezing tumors be redesigned to eliminate vapor locks without the use of heavy and bulky high-pressure gas cylinders? Is there a way to dispense foaming hand soap in a decorative pattern for a premium experience?

Getting the design right for a flowing substance can differentiate between a product that fails and one that creates an experience that shifts category norms and delivers breakthrough consumer delight.


References

Why testing is vital to product sustainability|

Making it last: Why testing is vital to product sustainability

How long do we expect a product to last? Many sophisticated technology products, such as phones and tablets, are routinely replaced after a few years as specifications evolve rapidly. But what about a chair or a toaster? There are a huge range of products that we only replace when they wear out, but how long will this take, and how do we decide when minor changes add up to justify a replacement? When we prepare new product designs, how do we test to predict whether the lifetime will be months, years, or decades?

The challenges of biomaterials

Many consumer products contain large quantities of plastics derived from crude oil. But there’s increasing consumer interest in products made from bio-based materials derived from plant matter. While bio-based plastics are renewable, many are recent innovations. There may be a temptation for designers to make a direct substitution between a well-established plastic derived from crude oil and a bio-based plastic. Yet the two materials are unlikely to behave on a “like for like” basis. Because of limited service experience, there’s often a lack of data or understanding of how new types of plastics degrade and age over time. As a result, long-term testing and lifetime predictions of bio-based materials is a particularly relevant topic and can begin right at the start of a design project, while still in the materials selection phase.

Designing for the long term

We want newly designed products to have a long service life and to withstand normal rough handling. If we buy a shiny new phone, bike, or car, we expect it to start looking slightly rough and worn after a while, but we don’t want it to break or change color too soon. How do we check for this? We need to think about how the product will be used and how it might fail.

We can look at this challenge in terms of material selection. How do products age under different applications? What types of rough handling will a product need to withstand, and will the result be sudden failure or a gradual loss of properties? How will subtle changes in the appearance of the product over time affect its suitability for continued use? Does it matter if it becomes less glossy or even changes in color? Is it easy to keep clean? Do certain design elements require local reinforcement to prevent early failures at potential weak points? It’s easy to overlook these questions when an existing product is redesigned, particularly if a change in material is proposed.

Even when changing the grade of the same plastic material, such as polypropylene, small variations in the amount or type of fillers and other additives, or the length of the polymer chains, can modify its behavior. We can’t look up a single set of properties for polypropylene as there are a huge number of grades with different characteristics. The impact of even a small change may be to move a design from rugged to marginal, with a substantially increased chance of failure. It’s vital to select specific tests in order to evaluate the risks for a particular application.

 

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Better, or just different?

There are many perfectly sensible drivers for changing materials, including cost or weight reduction, improvement in properties or sustainability. In each case we seek to improve, but have we unwittingly introduced a new way in which the product might fail? If the appearance or feel of the product has changed, might it be used differently? If it appears to be stiffer and more rugged, is it OK for me to push it harder? Have we considered how to test the product design to take all possible failure modes into account? If the customer could misunderstand how to use the product there’s an increased chance of unanticipated rough handling.

If we design a product to have a long lifetime, we also need to take customer preferences into account. Until recently, there were drivers to replace products simply because they look a little old and tired. But much greater awareness of environmental issues has encouraged customers to continue to use well-liked older products until they fail, and to consider repairing them to enhance their useful life. Whatever nature can create, nature can also degrade. So, if we consider replacing a synthetic plastic with a natural material, then it may be biodegradable under the conditions of use and so it may fail in new and unexpected ways.

Mechanical performance testing is always a good place to start. As well as testing the finished product, additional trials on small pieces, or “coupons”, of the component materials will highlight any changes in properties after environmental aging. For many regulated applications, such as medical, food packaging or toys, there are specific mandatory tests, for example measuring levels of extractable or leachable materials. But in a novel design it’s often other, non-mandated tests that show up how a particular product might fail. It’s then the responsibility of the designer to investigate and mitigate the possible failure modes in a new product. Key tests will show up early signs of wear, damage or other aging and it may not be necessary to test the item to destruction.

Taking it outside

If a product is to be used outdoors or at high or low temperatures, the risk of failure must be checked over a wide range of conditions. Artificial weathering environments with water spray and UV light mean we can quickly predict the impact of many years of outdoor exposure. As well as possible changes in mechanical performance, the stability of color and other aspects of appearance can also be tested. For example, we expect the paint on a car to begin to degrade only after many years.

Specific environments will put additional stresses on some types of materials. The salt in a marine environment or the sand in a desert may cause wear much more quickly. Beneath the hood of a gas-powered vehicle, the components will be exposed to high temperatures and oil, fuel, and other fluids. Materials used in aircraft, high voltage systems and nuclear power stations also need to perform reliably in very specific ways.

Standing the test of time

Long-term subtle changes can be difficult to detect. For example, many plastics undergo creep when subjected to loads and specialized test regimes are needed to detect when substitution with a stiffer material is necessary. Exposure to fluids can also cause long-term changes, particularly when plastics slowly absorb the fluid and become softened and distorted.

If a product is designed to last for decades, for example if it’s installed within a building, then we need to carry out accelerated aging evaluation to test how its properties will perform over this period. One response is to apply the rule that the rates of chemical changes increase with temperature in a predictable, mathematical way.

By storing samples in ovens at a range of elevated temperatures and testing them periodically, we can build a picture of how the same material will perform over decades at room temperature. This methodology is often termed the Arrhenius approach. For example, it may allow us to predict behavior after 10 years at 20°C in only around six months, by accelerating the testing at 60°C. We can even immerse the accelerated test samples in fluids if we want to simulate use in wet conditions, for example in food or beverage applications.

A route through the maze

With appropriate experience in design, material selection and evaluation, it’s possible to devise a new product and to put together a suitable test plan. The data generated can be applied to provide confidence that a new design or a change of material will lead to a product with a long lifetime. After all, when we like a pair of shoes, we want them to wear out slowly, and there’s no reason why the same can’t apply to our favorite products.

||Martha Hodgson||

Women in innovation: Design & Research

Women play a crucial role in innovation and business success at CDP. We’re proud of the critical contribution made by our women colleagues, who lead in diverse areas of innovation including design, research, science, technology, engineering and human factors.

In this first interview of Women in Innovation series, we talked to four of our leaders working in the design and research field. Thanks to Nicki, Martha, Millie and Clodagh for sharing their stories.

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Nicki Sutton | Senior Innovation Consultant

My primary role is generating insights for innovation and design through immersive and exploratory research. That insight or opportunity specification forms the basis for early-stage concept generation and it’s always important for the researchers to be in the room when that happens. It means they represent the users, customers or wider stakeholders and ensure that their needs are being translated correctly into design and design attributes.

Does being a female researcher give you different perspectives from a male researcher in the same position?

Honestly, and speaking just personally, I don’t think so. I believe any good researcher should be able to cross divides such as gender, age, culture, etc., to empathize with the challenges that individual groups can face. Of course, some subject matters are quite gender based, where one gender may have a very different experience from the other, or not have the experience all! For example, at CDP, we’ve worked on condoms, sex toys, body hair removal and femcare, however we’ve always had mixed gender teams on those projects. Perhaps the women were a little further up the experience curve on some of the insight, but I don’t think the guys were held back!

Have any female mentors supported you through your career?

Not really. My university courses and the companies I’ve worked for during most of my career have been mainly male dominated environments. Since joining CDP I’ve been among the most senior women employee-owners and so there has not really been much scope for female mentorship. However, I do get inspired by the work of other women in the company – in the ‘front end innovation’ team and the wider organization. I see some of the younger women – researchers, strategists, designers, engineers – and I’m in awe of their sheer talent and confidence! I definitely think that our education system, at both school/college and university level, better prepares you for life in the commercial world compared to when I was passing through it!

Do you have any design heroes that you look up to?

As someone who sits at the insight end of design, I couldn’t possibly answer this question without mentioning Clay Christensen; the founding father of disruptive innovation and Jobs to be Done (JTBD). Indirectly, he has been as influential on my career as anyone. JTBD has been at the center of my work for the last 13 years. It’s now a mainstream innovation perspective, but it was still in its relative infancy when I was introduced to it. Focusing on the jobs that people want to get done in their lives as the input to design and innovation seems very obvious now, but when jobs thinking arrived, we lived in a very product-centric research world. Companies believed that users and consumers were too difficult to understand – saying one thing and doing another – so they just didn’t bother with research or research was ‘market research’ into products already launched. Today we live in a different world of design and innovation. One in which jobs, not products, are the driving force of progress.

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Martha Hodgson | Market & Design Insights Research Consultant

My passion is design research: gaining an in-depth understanding of the stakeholder, whether that’s the end user, the commercial sponsor or the key decision maker who sits within a supply chain. Uncovering and understanding unmet needs are at the heart of creating meaningful and effective innovation.

Does being a female designer give you different perspectives from a male designer in the same position?

Being a female can help in understanding some specific contexts -for example, femcare– but I believe what makes a good design researcher is your ability to semi-detach yourself personally and empathize with the context and end-user audience that you are designing for.

Do you think being female has any relevance to how you approach your work?

I think I approach design differently to any other women or men because of the unique journey I have taken to get to where I am today. My approach at work is shaped by my empathy and my understanding of others. I also believe that starting my career as a designer has shaped the innovator I am today and enables me to help improve lives through innovation. It provided me with a way of looking at the world, asking the right questions, interpreting what I see and hear, and making new connections that have led to uncovering new opportunities. It is the combination of characteristics, values, skills and capabilities that is each of our differentiators.

Have any female mentors supported you through your career?

Yes, I’ve had incredible women mentors, and at the same time, I’ve also had excellent men mentors. I consider myself very lucky to have different role models throughout my life and career, and there have always been strong female leaders in the places where I have worked.

Do you have any design heroes that you look up to?

No ‘heroes’ as such! I admire many examples of achievement in many forms where someone has been driven by passion, gumption, determination and a lot of hard work! I follow a group called The Female Lead on LinkedIn, which I find very inspirational – it showcases and celebrates female success, and the many forms it can take.

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Millie Ashton | Industrial Designer

Ever since I was a small child I’ve had a passion for design – I’ve spent many hours designing Lego houses, ceramic animals and 3D printed plant pots to name a few examples. Being able to turn a nebulous idea into a tangible 3D object never fails to excite me, and the fact that I’ve been able to pursue a career in it makes me feel extremely lucky. I’m grateful that my role provides me with the opportunity to help people and bring joy to them through my designs. There’s great satisfaction in creating solutions that have the potential to improve people’s everyday lives.

Does being a female designer give you different perspectives from a male designer in the same position?

I’d like to think that there aren’t many disparities between men and women in our perspectives or design approach. However, it’s difficult to deny that being a woman means you naturally have a perspective that just over half the world’s population doesn’t have – this is invaluable and allows me to use that empathy to tackle problem solving. We take pride in creating design that is centered around user insight, which is key to producing a successful solution for all gender identities. As a woman, I can come up with ideas and new ways of thinking that my male counterparts may not have, and challenge society’s norm of designing for the average adult male.

Do you think being female has any relevance to how you approach your work?

Yes, at CDP I always try to bring a fresh mindset and perspective to problems. As one of the youngest designers in the design team, I enjoy challenging and questioning design norms, as well as keeping a finger on the latest product trends. As the only female member of the Industrial Design team, I try to bring female insight into the products we design and ensure we’ve considered how other genders might use the product differently. I also feel it’s essential to design for future generations, considering how a product’s life cycle will impact the planet in years to come.

Have any female mentors supported you through your career?

Throughout my education and career, many of my peers and lecturers have been male. I didn’t have a female mentor at university, but I wish there had been more female role models to look up to. It has been refreshing at CDP to witness more women joining the company and being promoted into senior positions and hopefully female mentorship in design is something that will continue to be improved upon in time, as more women take up roles in the design industry.

What would you want to say to the design industry or anyone thinking of working in design?

My biggest tip would be this: don’t be afraid of failure or rejection. What you may think is a stupid or crazy idea might turn out to be ingenious. If you love designing things, don’t let self-doubt get in your way – passion often leads to success, and saying yes to new opportunities is vital when starting out. Never stop learning or assume you know everything, and ensure you get as much design related work experience or internships as you can, to figure out your niche.

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Clodagh Hogan | Human Factors and Usability Engineer

My background is in pharmaceutical chemistry, but I moved into the medical device design world so that I could bring my hands-on design skills and scientific background to people-centered design. I’ve always loved being able to turn an idea into a physical object and working in design allows you to be creative every day.

Does being a female designer give you different perspectives from a male designer in the same position?

No. How I approach a design challenge is based on my mindset, creativity, experience and style of problem solving. I work with multiple designers and we all have different perspectives and different skillsets, but this is down to the fact we are different people, not that we are different genders. If men were asked to list the benefits of being a man in design, it wouldn’t be something that I’d want to read and I’d take it as a negative dig towards women. I believe in equality, which means we must recognize that different people have different skills and that gender doesn’t really play a role in it at all.

Based on your experience, what are the top challenges you have faced as a woman working in innovation?

The biggest challenge I face as a woman in innovation is this assumption that I face challenges because I am a woman. I am lucky to be at an early stage in my career while things are actively changing, and it will only get better as time goes on, but change cannot happen overnight. In the near future, I hope that questions like this are no longer asked because we will be living in a world where people no longer assume that women face challenges just because they are women.

Do you have any design heroes that you look up to?

I don’t have any one specific design hero, but there are many graphic designers, illustrators, typographers, UX designers and product designers that I spend a lot of my spare time following and getting both motivation and inspiration from.

What would you say to the design industry and future woman and men that would like to work in design?

I would say that if you are interested in design, then pursue it and don’t let whether you are male or female get in your way. If you are a woman starting out, you will see that there is an imbalance. More women are taking up careers and education in design and STEM now, but it will take time for there to be balance. Know that you are starting your career during an exciting shift and that you are part of this important movement.

We hope to use these ideas and perspectives to inspire other women and girls to pursue a career in design and innovation. Our women designers add enormous value to our projects and team, and we believe it’s essential to celebrate this diversity. In our next blog we’ll share more stories of Women in Innovation, here at CDP.

Dreaming big during COVID-19

Dreaming big during COVID-19

Product designer Laura Sierra is working with Cambridge Design Partnership as part of the marketing team. Here, she reflects on what she learnt during an international design competition, the Dream Big Challenge.

Laura says: I’m an industrial product designer from Colombia, now specialising in marketing and communications for the design world. I’ve studied for a Masters degree in Science and Marketing at Anglia Ruskin University. This led to me working on a project here at CDP, communicating all the amazing and innovative work the company does to the wider world.

In 2015, I had a wonderful opportunity to join a team competing in the Dream Big Challenge. It’s an international design competition for youth teams and to my surprise and delight, our team won. The whole experience was life-changing. Usually, the challenge takes place in a vast hall in Barcelona, where teams have just three hours to come up with disruptive and exciting solutions to design challenges.

This year, I was scheduled to get involved again. But, of course, Covid-19 meant that the plan for hundreds of young international designers getting together was never going to happen. The contest is sponsored by the likes of Santander and Nike. Cancellation would have been a major disappointment to all concerned.

But instead of giving up on the competition altogether, the organisers moved it online. So we competed anyway, using communications technology such as Zoom, working against the clock. This year’s online event attracted 900 competitors from all over the world. More than 350 projects were submitted, making this last-minute switch online a huge success.

My team chose to focus on the field of Education, as several of us had a keen interest in this area. In our home country of Colombia, a substantial percentage of children are not able to go to school and are also unable to reach the internet. So they miss out on education entirely. Could we think of a way to reach them?

To our delight, our project, called Ekko, scooped the third prize in the Education category. Our project was based on the idea of reaching children in remote areas via SMS messaging and radio. We aimed the project at pupils from 12-18 upwards, who could follow a class on the radio and interact with teachers via SMS. Many families have access to phones and radios in Colombia but do not have computers or access to the internet. And, of course, this model has potential in so many countries around the world. In Colombia, 47.7% of the population (23 million people) do not have internet access in their homes.

I learned a lot from the hectic three-hour webinar in which our team designed this education programme. Much of what I learned is proving very useful in my other online collaborative work during the Covid-19 crisis. Here is what I discovered about teamwork when you’re all working remotely under lots of pressure:

1. Have the right tools

I soon realised that it is important to have the tools which allow you to migrate between online and offline with ease.  Make sure you have digital tools, creative materials and can do (and share) fast sketching so that you can share ideas as seamlessly as possible. In the competition, colleagues were connected from other places, even in different time zones.  Working remotely using tools like Zoom, Google Meetings and WhatsApp was possible but also very intense. There is no doubt that online events change human interaction and experience. It is essential to have the proper tools to hand, allowing creatives and entrepreneurs to develop their projects remotely in a flexible and stress-free way.

2. Find your common purpose

A common aim really helps an online project. If you have a clear reason why you’re undertaking the work, things will be much easier. In our competition there was a choice of five different sectors: Health, Sport, Education, Work and Sustainability. I worked with university professors Andres Rubiano and John Higuera. All of us are passionate about social innovation and wanted to change education, making it fun, free and interactive. This really helped our motivation when things didn’t go smoothly.

3. Creativity is key

Using your imagination in challenging times is more important than ever. An open mindset allows us to manage challenges. I truly think that each day is an opportunity to learn and design a better world. The key is to let our imagination fly, allowing it to create and to not panic about failing. This competition taught me that, even during a lockdown, working remotely, it was possible to connect online, study other projects, explore new ideas and connect with new people.

In conclusion: I’m delighted to say that our project, Ekko, is now in the throes of becoming a reality in Colombia. It looks as though those tumultuous three hours of intense activity could end up changing the lives of thousands of children for years ahead. That really is a good result, isn’t it?

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The systems approach to formulation and product design

Today’s liquid and paste formulations, from washing up liquid to shampoo to toothpaste are complex structured fluids or solids which are designed to meet the demanding needs of consumers. It is tempting to regard the formulation or recipe as the main challenge. However, these complex formulations behave very differently in the range of environments they experience across their lifetime, such as manufacturing, filling, distribution, storage and consumer use – sometimes leading to unexpected failures. Should we adapt the formulation to work with the process/packaging or vice versa or both?

Seeing the Wood for the Trees

We take a systems approach to designing and developing new formulations. Put simply one must consider the interactions between manufacturing process, formulation, distribution chain, application device or packaging, regulations (monographs, storage requirements etc…) as well as consumer habits and usage requirements. This has long been the goal of all product development groups but reality is often different.

Often there is a focus on only some of these parameters, for example the formulation, packaging, regulatory and consumer attributes, and then a huge effort is subsequently spent trying to adjust the manufacturing and distribution chains to accommodate the product – incurring unnecessary cost and time delays to new product introduction. This has a huge and often neglected economic impact, from personal experience this can add as much as 5% to the total delivered cost of the product.

Putting the Toothpaste back into the Tube

Many real-life examples exist of these manufacturing issues. These include a shampoo product, where the manufacturing line speed had to be turned down to prevent issues with filling bottles, such as dripping, mounding and air entrapment. Another was the high level of product rejects due to incomplete sealing of toothpaste tubes caused by the formulation stringing during filling. A third was the eventual upgrade, at a significant cost, of filling lines to accurately dose out a structured fluid and prevent periodic under-filling.

These solutions were a consequence of an incomplete understanding of how to design a recipe to cope with manufacturing and filling where there are quite extreme forces and shear rates involved. Recent advances in rheological equipment and methods, coupled with Computational Fluid Dynamic modelling now enable formulators to simulate these conditions and explore strategies to reduce or eliminate these issues. We have reached a tipping point where formulators can now actively design complex fluids to be easily prepared, as well as fulfil their other design criteria thus potentially avoiding unnecessary costs.

Delivering the Optimum Four-season Solution

Many companies are exploring new e-Commerce business models with products being distributed directly to the consumer, bypassing large parts of their centralised distribution network. This presents an interesting challenge to ensure products and packaging are designed to survive shipping and still deliver the intended consumer use experience. To help solve this puzzle it is important to obtain real-world data of what actually happens to your package before it reaches the consumer. Does it freeze in the middle of winter in Canada, or bake during the height of summer in Florida? Does it experience massive pressure swings as part of air freight causing packs to burst open? How often does the temperature cycle from high to low and back again, and how much vibration or shock loading does your pack receive?

All of these considerations can have a drastic impact on the integrity of your product and brand image and affect consumer acceptance. It is important to put together a testing protocol to verify that the formulation and packaging solution are sufficient to cope with any extreme conditions. We have experience fitting customised tracking sensors inside packaging and if necessary inside the pack itself. This enables real shipping or usage experiments to be run and high quality data collected to guide product design and stability requirements.

Putting it All Together

At CDP we have access to tools and techniques which can be used to explore important design spaces for formulated products, to avoid unnecessary costs and exploit new ways of doing business. Our broad combination of experience in Chemistry, Consumer Insights, Materials Science, Packaging design, Modelling & Simulation, Digital Systems, Manufacturing Technology and other areas can help you to take more control over your design space and specifications.

We do not specialise in just one area, instead we have experience in how all these aspects can work together across several industries, so that we can adapt and combine approaches from entirely different applications.

The recipe may be at the heart of the product, but it must work with the package and the process to provide the best possible customer experience.

New Biolab for CDP’s HQ

CDP has just opened a brand-new biological laboratory at its Cambridge HQ, certified to allow research on containment level 2 biological hazards such as micro-organisms, blood and other body products.

‘We are delighted to announce that our new lab has now received approval from the UK Health and Safety Executive,’ says Dr Richard Owen, CDP’s senior bioscience consultant.

‘This new facility allows CDP to grow and handle a wide range of different microbial pathogens including bacteria, viruses, fungi and protozoa as well as animal and human blood, bone and tissue samples.’

The lab will allow CDP’s scientists and engineers to work on projects such as medical diagnostics, insulin-testing for diabetes and other health-related projects in-house at its Cambridge base. Previously, such research had to be out-sourced to external partners.

Richard, who joined CDP in the summer of 2018, set up the facility and generated the appropriate protocols and documentation so that it meets the required specifications. Richard has extensive experience in researching medical products and previously co-founded a start-up at Papworth Hospital in Cambridge. He says, ‘I am delighted to add this capability to CDP’s range of product development services. It is the final piece of the jigsaw that allows CDP to offer end-to-end development of diagnostics assays, instrumentation and medical devices.’

Dan Haworth, CDP’s head of diagnostics, also welcomes the news: “Here at CDP, we have previously developed a range of diagnostic platforms and now have the capability to carry out performance testing in-house with viable micro-organisms. This will greatly speed up our design process.’

Matt Brady, head of medical therapy at CDP, adds: “This new facility allows us to do early-stage concept testing with clinical samples as well as full verification and validation studies in-house. Our clients will benefit hugely from the full testing capability we are now able to offer.’

For more details, contact Dr Richard Owen on: Richard.Owen@cambridge-design.com

Satmap Active 20 Collaboration

Satmap Active 20 Collaboration with Satmap Systems to create the ultimate rugged, high-performance sports GPS device

The Challenge

Following the success of its Active 10 and Active 12 GPS devices, Satmap Systems decided to create the next generation of Active devices – with improved screen toughness, button functionality and waterproofing. It also wanted to incorporate new features such as a touchscreen, Wi-Fi connectivity, improved GPS and a unique dual-battery system.

APPLIED EXPERTISE

  • Research & strategy
  • Human factors
  • Industrial design
  • Packaging
  • Technology development
  • Mechanical engineering
  • Electronic engineering
  • Software engineering
  • Wireless & connected
  • Short run manufacturing
  • Manufacturing processes
  • Supply chain management

The Solution

Our first step was to gain human factors insights and gather customer feedback from previous models to feed into the design process. Our industrial design team then worked to maintain and enhance the brand, while our engineers integrated the new functionality and developed the mechanical design to meet the extreme requirements of Satmap customers.

Proof-of-concept tests ensured that the custom Gorilla Glass touchscreen within the ultra-rugged case design exceeded IK7 grading in impact tests and achieved IP68 rating for water submersion.

Benefit to Client

The new Active 20 was a sell-out success within days of its launch.

“We’re really pleased with the Active 20 – we’ve integrated all the exciting new technologies we were hoping to, while maintaining our customers’ favourite features. We are confident the Satmap experience will be better than ever.”

Howard Dyson, managing director and founder, Satmap Systems