Last-mile
Vaccine Delivery System

for ENHANCED INNOVATION

2024 - 2026

#Medtech #Medicaldevicedesign #Productdesign #Industrialdesign #Startupproject #Healthcare #Handhelddevice

"Our investors called our first prototype a rat catcher ! "

- Prerit Mittal , Founder

SCOPE OF WORK

Product Design

Design Engineering

Prototype + Testing

Pilot Batch Assist

From “Rat Catcher”
to Market-Ready

Challenge: A functional vaccine refrigerator failed to gain investor trust due to poor form, fragmented engineering, and vendor misalignment.

Intervention: Took ownership of full product development — from UX and industrial design to engineering, sourcing, and pilot manufacturing.

Outcome: A production-ready, IP65-certified medical device that restored investor confidence and positioned the startup for deployment in remote healthcare settings.

Enhanced Innovations identified a critical gap in last-mile vaccine delivery: reliable cold-chain infrastructure is difficult to maintain in resource-limited environments.

Their ambition was to develop battery-powered active cooling systems that could work anywhere, for anyone, under demanding conditions.

Yet most existing devices were bulky, industrial, and impersonal — not something a health worker could hand over with confidence, or a community could trust on sight.

CONTEXT

The Urgency of
Cold-Chain Gaps

DESIGN STRATEGY

Where Constraints shaped the form

Manufacturing budget was the one fixed constraint. Form, usability, and feel were trade-offs we worked through with the client, not requirements handed down. The architecture followed: thermoforming, sheet-metal fabrication, and vacuum casting, built for low-volume production.

Compact architecture — We reworked the original side-by-side layout into a vertical battery-and-cooling stack, cutting the footprint — which raised a new problem: stability with the lid open. A wider base and tapered body solved it.

Soft body, structured handle — Rounded corners strengthened the thermoformed shell and added a friendly character in one move. A sharper, fixed handle added visual weight, cut mechanical complexity, and created a grab-and-go feel. A hood was introduced to redirect hot exhaust away from the hand. We extended the handle further to house the controls and indicator lights, folding a structural part into the product's interface.

ADDING THE FINER DETAILS

Engineering
the Intent

The lid lock was custom-built for one-handed opening in the field, its geometry shaped to sit flush with the tapered body rather than break its line.

A lid stopper limits the opening angle, preventing the lid from being pulled past 180° and stressing the hinge.

The internal sheet-metal structure was refined for assembly efficiency — modular sections, simpler joins — while holding the 5.5 - 6 kg target weight.

Thermoformed parts were given slide-lock fitment instead of screws, cutting fastener count and giving the final assembly a cleaner, more considered finish.

Iterate, Refine,
Protect the Vision

From
Prototype to
Product

Testing surfaced specific problems that reshaped the design through several loops. Gasket geometry and shore hardness were revised after early prototypes showed thermal leaks. The lock was refined for structural strength and spring tension after field handling. The handle was reworked for ergonomics and easier assembly. Plastic parts were re-optimised for strength through the same cycles.

We oversaw material sourcing, vendor coordination, and engineering alignment — ensuring each change preserved the original design intent while meeting manufacturing feasibility.

OUTCOME

Certified for the Toughest Conditions

With a few targeted iterations — foam tapes, silicone caps, and covers — we achieved IP65 certification alongside medical certification testing, reinforcing readiness for market and restoring confidence in the venture's vision.

When unveiled to investors, the redesigned Phloton Alpha drew a new comparison: "It looks like a premium air purifier" — modern, trustworthy, and aspirational. The distance from "rat catcher" to that comparison is the real result: one team holding the intent from concept through sourcing to manufacturing meant testing sharpened the design instead of eroding it.

The design shipped: Enhanced Ennovations secured a 40-unit pilot batch, now reaching early adopters while the venture continues investor conversations. Phloton Alpha stands as evidence that design-led ownership — not just design-led styling — is what carries intent from concept into a certified, deployed, life-critical product.