Technologies: EDM, CNC, VC, sheet metal
                                Materials: aluminium, steel, Pb, brass, copper, ABS, PA
Planned production volume: 1 main device, 1 charger and 2-6 accums (true and fake)
          Operating conditions: outdoor, IP66, from -25 to 60°C
               Protection against: X-rays, impact, and overheating (of sensitive electronic components)
                                  My role: Design engineer, industrial designer
  Time spent on the project: 672 h.
                  Project duration: 13 mo.Â
What's this?
This device is a mobile X-ray detector, similar to the stationary units used in dental clinics, for example, but portable. It captures, records, and transmits (wired or wirelessly) the X-ray exposure of an object positioned between the X-ray emitter and the detector. This type of device is primarily used in industrial non-destructive testing, such as inspecting welds on pipelines in remote areas or directly on the production floor.
Initially, the client needed only a fully functional demonstration unit (detector + accumulators) for market research and discussions with potential customers, such as factories and maintenance organizations. Later, as the project evolved, client decided to create a mains-powered configuration by replacing the "true" accumulators with "fake" ones — one acting as a circuit bridge and the other enabling power input. Eventually, he also decided to develop a dedicated battery charging base.
My role was to take the electronic components (X-ray receiver 1515DXT, computer WAFER-BT-i1, circuit boards, and an off-the-shelf battery 38120S), which together form the functional electronics, and "package" them into a market-ready product by developing both the internal structure and the external enclosure (since one defines the other, this distinction is somewhat arbitrary).
Initially, the charger enclosure was planned to be custom-madeÂ
and I engineered this version with a metal top for heat dissipation, as it was necessary to divert heat from the electronicsÂ
Later, it was decided to use a stock enclosure from Gainta as a more cost-effective solutionÂ