Improving serviceability and reducing cost in a piece of complex laboratory equipment
The Packard TopCount is a high-throughput microplate screening instrument used to analyze scintillation and luminescence samples in pharmaceutical and life-science research. While the system delivered strong analytical performance, its internal construction created challenges for manufacturing efficiency, service access, and overall cost.
Packard Instruments engaged DiMonte Group to improve the design of the TopCount’s enclosure and internal architecture—reducing cost of goods while maintaining performance and reliability.
The Challenge
The original TopCount design relied heavily on layered sheet metal assemblies, extensive fasteners, and sealing tape to achieve light isolation within the sample chamber. While effective, this approach introduced several issues:
- Time-consuming assembly and service procedures
- Higher manufacturing and material costs
- Limited accessibility for maintenance and repair
- Opportunities to improve light sealing and internal performance
The redesign needed to simplify construction, improve serviceability, and reduce cost—without compromising the instrument’s analytical integrity.
Our Approach
DiMonte Group approached the redesign with a strong focus on Design for Manufacturing and Assembly (DFMA).
Our team conducted on-site DFMA reviews, evaluated existing assemblies, and met directly with manufacturing vendors to understand cost drivers and fabrication constraints. These insights informed a re-architecture of the enclosure system that reduced part count, simplified assembly, and improved internal access.
Design & Engineering
DiMonte Group redesigned the TopCount enclosure using a hybrid approach that combined molded skins with simplified sheet metal structures. This strategy allowed the team to:
- Eliminate sealing tape by integrating improved light-sealing geometry
- Reduce the number of fasteners required for assembly and service
- Improve access to internal components for maintenance and repair
- Maintain and improve optical performance within the sample chamber
The revised design balanced manufacturing efficiency with durability and performance, resulting in a cleaner, more serviceable instrument architecture.
Outcome
The redesigned TopCount enclosure delivered measurable business and user benefits:
- 20% reduction in unit cost of goods
- Improved serviceability and reduced maintenance time
- Simplified manufacturing and assembly processes
- Enhanced internal light sealing and performance
This project demonstrates DiMonte Group’s ability to apply DFMA principles to complex laboratory equipment—driving real cost savings while improving usability and long-term product value.
