SENIOR INDUSTRIAL DESIGNER
C-Arm X-Ray System Redesign
Fluid-Safe Emitter Architecture for Surgical Environments
Industrial Design | Medical Devices | Product Architecture | Production Design
Client: Tivitron Healthcare
(Previous architecture by Philips)
Context / Brief
C-Arm X-ray systems are mobile imaging devices used in operating rooms when patients cannot be moved to fixed radiology setups. With five axes of movement, the C-shaped arm positions an X-ray emitter below the operating table and a receiver above the patient, enabling real-time imaging during surgery.
Tivitron’s C-Arm platform was originally based on an emitter and receiver architecture developed earlier by Philips. While functionally proven, the existing enclosure design revealed critical shortcomings when exposed to real surgical conditions, particularly related to fluid ingress at the emitter unit located beneath the operating table.
Problem Statement
In the existing C-Arm system architecture, the X-ray emitter enclosure was constructed using a left-right split housing, joined along a central vertical seam and sealed with rubber gaskets.
During surgical procedures, blood, saline, and disinfectant fluids frequently drip from the operating table directly onto the emitter unit. The vertical seam between the two enclosure halves created a vulnerable channel where liquids could accumulate and, over time, penetrate inside despite sealing.
This resulted in:
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Internal component contamination
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Electrical and sensor failures
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Increased service and downtime
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Reduced reliability in critical operating room environments
For a life-critical imaging system, even minor fluid ingress posed unacceptable risk.
Design Rationale
The original emitter enclosure relied on a left-right split that allowed surgical fluids to collect and seep into the unit. The redesign treats enclosure geometry as the primary defense, using gravity to actively shed liquids rather than relying only on seals.
Design Solution
The housing was re-architected into a top-bottom clamshell with an extended upper shell that diverts fluids away from critical joints and eliminates pooling. The same language was applied to the receiver, resulting in a cohesive, fluid-safe C-Arm design now approved for production.
