Project Overview
Empo Health approached Mosaic with an urgent need: develop a functional proof-of-concept prototype for their revolutionary imaging bathroom scale in time for a critical clinical validation study. The device is designed to assist diabetic patients and their doctors with at-home visual inspection of feet, enabling early detection of diabetic foot ulcers before they result in serious complications.
The challenge was integrating a sophisticated imaging sensor into a low-profile bathroom scale form factor—and doing it in under 8 weeks to meet the clinical study timeline.
Technical Challenge
Diabetic foot ulcers are a serious complication affecting millions of patients, often leading to amputation when not detected early. Empo’s vision was to create a device that patients could use daily at home, capturing images of their feet automatically during routine weighing. This required:
- Low-profile integration: Imaging sensor must fit within the height constraints of a bathroom scale
- Robust imaging: Capture quality images in varied home lighting conditions
- User-friendly operation: No special positioning or setup required by patients
- Clinical validation ready: Prototype must be reliable enough for clinical testing
Solution Approach
Rather than designing a custom sensor system from scratch—which would have taken months—Mosaic took a pragmatic approach:
Rapid Prototyping Strategy
- Off-the-shelf sensor integration: Identified and adapted an existing imaging sensor from a commercial product
- Custom mechanical design: Engineered mounting components to integrate the sensor into Empo’s scale form factor
- Iterative development: Rapid prototyping cycles to validate fit, function, and image quality
- Clinical-ready build quality: Ensured prototype durability for patient testing
Key Design Decisions
- Leveraged proven sensor technology to minimize risk and accelerate timeline
- Designed custom mechanical interfaces for seamless integration
- Optimized optical path for foot imaging within height constraints
- Validated image quality with Empo’s clinical team before final delivery
Optical Simulation & Tolerance Analysis
Beyond the physical prototype, Mosaic developed custom ray tracing simulation software to help Empo understand how manufacturing variability would affect imaging performance of their large-area microlens array.
Monte Carlo Simulation Tool
- Custom Python GUI: Built using open-source ray tracing libraries for optical simulation
- Manufacturing tolerance analysis: Evaluated impact of component variations on image quality
- Point spread function analysis: Quantified system resolution under different conditions
- Image quality prediction: Simulated performance using test data to guide design decisions
This simulation capability allowed Empo to make informed decisions about manufacturing tolerances and design specifications before committing to production tooling, reducing risk and accelerating development.
Deliverables
- Functional prototype: Fully integrated imaging scale ready for clinical testing
- Optical simulation software: Custom ray tracing tool for tolerance analysis
- Documentation: Assembly instructions and technical specifications
- Timeline: Delivered in under 8 weeks from project kickoff
- Clinical validation support: Ensured prototype met requirements for patient studies
Impact
The prototype enabled Empo Health to proceed with their clinical proof-of-concept study on schedule, validating their innovative approach to diabetic foot care. By thinking creatively about component integration and moving quickly, Mosaic helped Empo advance their mission to prevent diabetic complications through accessible home monitoring.
This project demonstrates Mosaic’s ability to deliver practical solutions under tight timelines—understanding when to leverage existing technology and when to design custom components, always keeping the client’s goals and constraints in focus.
Need a rapid prototype for clinical validation or investor demos? Contact us to discuss how we can accelerate your product development timeline.