New Product Design and Development Case Studies

Product Development: The MD2 is the most all-encompassing example of ESCA's product development know-how

Medical Appliance Product Development: ESCA Inc. was the product design and development arm of a Midwest medical appliance start-up company. Two related products were successfully launched and produced. Both products were centered around the company's patented MD.2 medication dispenser. The MD.2 is used in the home and designed to be very user friendly. One version delivers medication exclusively, while the second version includes a fully integrated Personal Emergency Response System (PERS). A major home healthcare company purchased the MD.2 in 2009.

ESCA Inc. has been involved with this start up effort from product inception through full support of production. Electrical, software and mechanical concepts and designs were developed at ESCA Inc. Plastic part design and tooling fabrication were managed by the ESCA Inc. staff.db _pic

Transition to production, as well as complete manufacturing, special factory test equipment development, and a repair / refurbishment depot were provided by ESCA Inc.

A sophisticated SQL based client/server database application was also developed to support remote set up of the product in the field, as well as providing daily operational statistical collection and a caregiver back-up for alert handling (e.g. missed dosage alerts).

Electronics Development: The following are just a few examples of ESCA 's electronics development capabilities


LCD Controller Interface: Designed a serial interface and LCD display module driver interface card for ImageTek Inc. This circuit board and firmware design needed to be completed quickly to meet ImageTek schedule, we delivered early, on budget , and without need for any rework or redesign.


Controller and Motor Driver: Redesign of a microcontroller based stepper motor drive electronics circuit board for a custom Avery Dennison Inc Label Attacher. The electronics drove the attacher electro-mechanical apparatus and communicated via a USB connection to a host PC for settings and attachment speed.

Software Application Development: The following are just a few examples of ESCA's software development capabilities

product design & development, custom product design and development

Interactive Sheet Music Display: ESCA Inc. developed a sophisticated software application for the consumer market.  The app, Digmus, is a patented, electronic sheet music display apparatus. Computer file-based music sources are interpreted, then converted to electronic sheet music for the performer to read. The application furthermore listens to the performer's playing of the music, following along and indicating what notes or chords the performer is playing. Automatic page turning is handled so the performer can concentrate on the performance and not flipping conventional paper- based sheet music.

Milling Machine Custom User Interface: ESCA Inc provided a Java base GUI for DATRON Dynamics sophisticated high speed milling station. The  GUI, Datron MillMark, is used by the operator to select a die component based on key die parameter, from the custom designed die data base for milling. Upon selection, the GUI generates a settings file for use by Datron Milling software to mill the die(s) component.


3D Printer Application Driver:  ESCA Inc adapted and redesigned the  Solidscape Inc , a Stratasys Company 3Z Printer software driver into a .dll . Working closely with software applications content experts from Solidscape, we designed and developed a new software interface package, installable in .dll form, for CAD vendors and software-sophisticated end users of Solidscapes 3D printer.

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