When IRIDEX needed to modernize their aging retina laser system while also reducing manufacturing costs, they turned to the team at StudioRed.
The catch? The heart of the device — the core laser itself — accounted for half the manufacturing cost, and we couldn’t replace it. We applied our 40+ years of industrial product design experience to navigate this high-stakes task, transforming the look and feel while reducing costs by 20% and improving the product’s functionality.
Results at a glance:
- Achieved a 20% manufacturing cost reduction despite fixed core components
- Streamlined manufacturing process with direct collaboration between StudioRed and manufacturers
- Modernized aesthetic design with a clever color-coding system for multiple product variants
- Enhanced user interface, improving operator experience
- Significantly improved serviceability, reducing long-term maintenance costs
- Accelerated time to market compared to internal development timeline
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“I don’t know how we could have made it [cost less] and still be as durable, nice looking, and as functional as it is.”
– Ken Arnold, former VP of engineering at IRIDEX
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IRIDEX: Pioneering Laser Technology in Ophthalmology
IRIDEX, a leading laser ophthalmology company with over 40 years of experience, specializes in laser-based medical technology for retina and glaucoma treatments. When Ken Arnold, VP of engineering at IRIDEX, needed to develop their next-generation retina laser system, he turned to StudioRed, a partner with whom he had collaborated successfully for over 20 years on various engineering challenges.
The Challenge
IRIDEX was operating with a retina laser system that, while reliable and effective, was showing its age. The product was approximately 15 years old and featured an outdated medical device design and user interface that no longer reflected the company’s innovative technologies.
Ken and his team faced multiple challenges prior to partnering with StudioRed:
- The urgent need to rapidly bring a new, modernized product to manufacturing to refresh their offerings and remain competitive
- Limited internal engineering resources, with most staff committed to sustaining engineering and addressing immediate production line issues
- The need for a modern aesthetic that would appeal to contemporary medical facilities
- A requirement to create visual consistency across multiple wavelength laser platforms
- The critical goal of reducing manufacturing costs by 20%, even though the core laser component — representing roughly half the product cost — couldn’t be modified
- A requirement to meet critical performance standards, including drop and shock resistance, vibration stability, electromagnetic interference (EMI) compliance, and precise thermal management for the internal laser components
Internal development would have meant pulling engineers away from critical day-to-day operations, creating potential problems on existing production lines. And without specialized expertise in cost-effective design for manufacturing, the ambitious cost reduction target would likely remain out of reach.
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“It was obvious from the beginning that if we tried to do it internally, it would take far too long, and it probably wouldn’t be optimal because we didn’t have internal resources who were skilled or practiced at this type of packaging. Regardless, even if we did, the internal resources we had were fully consumed in sustaining engineering activities.”
– Ken Arnold, former VP of engineering at IRIDEX
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The Solution
We approached the IRIDEX project with our comprehensive trademark methodology, addressing not only the immediate design needs but also long-term manufacturing and serviceability considerations.
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“Many years ago, we went to a big-name industrial design firm, and they did sketches for months of crazy stuff that looked like spaceships and had nothing to do with the actual product or its usage. But then I came across Phil at StudioRed, and when we sat down, he asked about the environment the product would be used in, where it would sit in the operating room, who’s using the controls, and where it would be positioned relative to the other equipment.”
– Ken Arnold
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We had a six-month timeframe, from the initial engineering to the handoff to manufacturing, so we needed to be strategic with our process. Recognizing the limitations of IRIDEX’s internal resources, we took complete ownership of the engineering, building upon the defined industrial design to create a robust and manufacturable solution.
We structured our approach around a clear three-phase engineering process:
- Phase 1: Precision 3D modeling: We started by creating detailed 3D models of the redesigned laser system, laying the foundation for all subsequent engineering and manufacturing considerations.
- Phase 2: Iterative medical device prototyping: Our team rapidly built 10-15 functional prototypes, allowing for thorough testing and validation. We swiftly incorporated the learnings from each iteration, optimizing the design and addressing potential issues early in the development cycle.
- Phase 3: Collaborative manufacturing integration: Recognizing the critical importance of a smooth transition to production, we engaged with IRIDEX’s manufacturer early and addressed all of their questions to ensure a complete understanding of the design specifications.
Our goal when working with IRIDEX during the design process was to combine function, aesthetics, and manufacturability in a practical way. We also provided IRIDEX with some initial supply while they transitioned to their long-term overseas manufacturer.
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“StudioRed was wonderful in supporting the transition to manufacturing. We could have ordered more, but we thought 50 [initial units] gave us plenty of time to actually bring up the long-term supplier without a lot of risk.”
– Ken Arnold
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Our team couldn’t replace the core laser module, so we had to find savings in the remaining components, effectively doubling the efficiency improvements needed in other areas.
Here are the steps we took to achieve this goal:
- Redesigned the enclosure with more efficient sheet metal designs
- Simplified internal mounting structures without compromising durability
- Replaced unnecessary, expensive bracketry with more cost-effective solutions
- Transitioned select internal components from metal to plastic where appropriate
- Improved serviceability to reduce maintenance costs over the product lifecycle
- Streamlined the assembly processes
Beyond product development cost considerations, our team developed an efficient solution to distinguish between different wavelength lasers in IRIDEX’s product line. Rather than using expensive custom bezels or complicated markings, we designed a simple yet distinctive color pinstripe that could be easily swapped out for different models.
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“Each laser is identified by a different color, but we wanted a common enclosure for all of them …[StudioRed] came up with a really clever solution, a color stripe feature along the side. It added a nice flair to the look, and it was a separate piece, so you could put whatever color in there you wanted. This was a big deal because previously, customers with multiple lasers couldn’t easily tell which laser was which. This made it blatantly obvious.”
– Ken Arnold
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This innovative approach solved a real user problem — previously, medical staff had to check labels on the back of units to identify which wavelength laser they were using — while maintaining aesthetic consistency and minimizing additional manufacturing costs.
The Impact
Our work delivered several benefits that continue to generate value for IRIDEX.
Immediate financial impact:
- 20% manufacturing cost reduction across the product line
- Reduced time to market compared to internal development
- Efficient manufacturing transition without production interruptions
Operational improvements:
- Enhanced product identification with a color-coding system, eliminating confusion in medical facilities with multiple units
- Significantly improved serviceability, allowing technicians to access and replace components at a lower cost and without disassembling the entire unit
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“StudioRed is not only great at figuring out how to best assemble it, but also how you’re going to work on it. What if you have to go in and change a part? How big of a deal is that? Before, you had to tear the whole thing apart. Now, you can access and replace key components more easily.”
– Ken Arnold
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Market and brand benefits:
- Modernized aesthetic aligning with IRIDEX’s innovative reputation
- Improved user interface, enhancing operator experience
- Consistent design language across product variants, strengthening brand identity
The product redesign not only addressed immediate cost and aesthetic concerns but also established a foundation for long-term operational efficiency. By improving serviceability, IRIDEX benefits from reduced maintenance time and costs throughout the product lifecycle, directly impacting their service contract business.
Two Decades of Trust: IRIDEX’s Former VP of Engineering on StudioRed’s Consistent Excellence
Ken Arnold’s 20-year relationship with StudioRed is due at least in part to our consistent quality and practical approach. After underwhelming experiences with larger industrial design firms that focused on creating designs without practical manufacturing considerations, Ken found StudioRed’s approach refreshingly different.
Our comprehensive approach delivers solutions that not only look good but work well, can be manufactured efficiently, and provide long-term value.
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“I have 20-plus years of history with StudioRed, and they have maintained a strong team that delivers high quality and practical designs. In my experience, they are a great partner to work with, they’ll support you well through the entire process.”
– Ken Arnold
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Experience the StudioRed Advantage
IRIDEX’s success story demonstrates why leading medical device companies choose StudioRed as their product development company partner. By combining aesthetics with practical engineering expertise and manufacturing knowledge, StudioRed delivers solutions that reduce costs, improve usability, and create long-term value through thoughtful design.
Whether you’re looking to modernize an existing product, reduce manufacturing costs, or bring an entirely new concept to market, StudioRed’s proven approach ensures your project will be executed with efficiency and practical excellence.
Contact StudioRed today to discuss your project needs and discover how our integrated design and engineering approach can deliver measurable results for your business.
