The prototyping process with the IDEO.org Evotech team takes some twists and turns as the team works to complete an endoscopy device prototype for pilot distribution around the world.

We've been on quite a journey with Evotech in the last three weeks. As a quick recap of what we’re designing, one part of the endoscopy device consists of an off-the-shelf eyepiece and coupler attached to an iPhone-style camera. We’re designing the handle and waterproof casing for this part of the system. In less than a month on the project, guided by doctors’ feedback along the way, we’ve built 11 iterations of this handle. We're also designing a heat sink and enclosure for the device's LED light source, with all of this plugging into the USB port on a computer so that the device can be powered remotely.

This is an interesting product because we only plan to produce about 100 units for pilot distribution to NGOs that can benefit from access to endoscopy. With the lessons from this pilot, Evotech should have a much clearer idea of which markets will benefit the most from low-cost endoscopy and where to focus its efforts in the future. The current design has enough flexibility to be used for diagnoses in urology and gynecology (for procedures such as hysteroscopy, cystoscopy and laparoscopy) and will also help to more accurately diagnose fistula and cervical cancer.

The early designs for the handle were quick, hand-carved foam models used to test out different ways to hold and interact with the device. These models led us to a design that routs the camera cable out of the front of the device to connect with the LED light source. The advantage of this design is that the two cables can now be routed together, minimizing distractions during surgery. We then explored a variety of handle sizes and shapes in this configuration, using 3D printed models to more easily tweak the design as it evolved.

Some interesting feedback we got was that everyone who tested the models wanted to hold the handle upside down. We had raised a section of the handle to make it easier for the hand to determine when the camera was vertical, but in doing so misguided people in the best way to hold the device. With a few tweaks, we corrected the situation and arrives at the final handle design.

We're currently assembling the final machined parts and planning to have a waterproof and working solution in the next two days.