Medical device development has traditionally relied on physical prototypes, bench testing, and iterative redesign. While effective, these methods are time-consuming, costly, and risky when working under tight timelines and regulatory scrutiny.
Today, digital solutions are transforming Medtech innovation. Tools such as simulation, digital twins, data visualization, and immersive virtual environments allow engineers to test, validate, and refine devices before they are ever built. These methods reduce costs, accelerate development, and improve confidence in regulatory submissions.
At Boston Engineering, our Digital Solutions Center of Excellence (COE) leverages these tools to de-risk development and empower innovation. By combining digital methods with our systems engineering discipline and other COEs, we help innovators validate ideas earlier, refine designs faster, and deliver safer, smarter devices to market.
At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:
Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X
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Physical prototyping has always been a cornerstone of medical device engineering. But without digital acceleration, innovators face significant hurdles:
Without digital methods, teams risk longer development cycles, higher costs, and slower adoption.
Boston Engineering’s Digital Solutions COE provides a range of capabilities that transform how medical devices are designed and validated:
These tools don’t replace physical testing — they complement it. By catching problems early and refining designs digitally, we ensure physical prototypes are built with greater confidence and fewer surprises.
Boston Engineering has applied digital solutions across a range of medical technologies, including:
While some view AI as a potential job replacement threat, the reality is that these advanced capabilities are better positioned as “workforce multipliers” that will amplify the abilities of doctors, nurses, technicians and other medical professionals.
A medical technology company approached Boston Engineering with a new surgical navigation system. The device had advanced capabilities, but clinicians found the interface unintuitive and difficult to integrate into their workflow. Physical prototypes were expensive and time-consuming to modify, slowing progress toward regulatory readiness.
Our role:
The outcome:
Across programs, Boston Engineering’s Digital Solutions COE has enabled innovators to achieve:
Digital solutions are no longer optional in medical device development — they are essential to competing in a fast-moving, high-stakes industry. By embracing simulation, visualization, and virtual testing, innovators can build smarter devices faster, with less risk and greater confidence.
At Boston Engineering, our Digital Solutions COE brings the tools and expertise to make this possible. By integrating digital methods with our robotics, embedded systems, control systems, and DfX COEs, we create a digitally empowered systems engineering approach that accelerates innovation and ensures success.
Whether you’re designing surgical tools, diagnostic platforms, or connected care devices, Boston Engineering can help you leverage digital solutions to reduce risk, accelerate development, and deliver devices that transform patient care.
In this eBook, we’ll dive into the real-world experiences of DFX subject matter expert John DePiano, exploring the common areas where existing product owners excel, as well as the key opportunities where targeted DFX support can drive major improvements.
Understanding the Importance of a DFX approach in medical device design & development
Applying Design for X (DFX) methodologies upfront in medical device development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.
Do you offer training on DFX for your medical engineering teams?
Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio.
Ready to Begin your next medical device DFX Project?
No matter the challenge, our team possesses the expertise in the engineering disciplines and technologies you need to bring your vision to life. Impossible Challenge? Try Us.
Impossible Challenge? Try Us.
Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.
The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace. Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.
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