SonoBone

SonoBone

SonoBone

A cutting-edge robotic ultrasound bioprinter for patient-specific bone repair, developed in collaboration with ETH Zurich.

The Client's Challenge

The Client's Challenge
The Client's Challenge

A bioprinter that’s as beautiful as it is powerful. The project required a design that could satisfy several key technical and business needs:

Performance

The system needed to be structurally robust enough to support a robotic arm for high-resolution, repeatable bioprinting.

Performance

The system needed to be structurally robust enough to support a robotic arm for high-resolution, repeatable bioprinting.

Performance

The system needed to be structurally robust enough to support a robotic arm for high-resolution, repeatable bioprinting.

Performance

The system needed to be structurally robust enough to support a robotic arm for high-resolution, repeatable bioprinting.

Performance

The system needed to be structurally robust enough to support a robotic arm for high-resolution, repeatable bioprinting.

Biomedical Compliance

Every material had to be biocompatible and suitable for advanced tissue engineering applications.

Biomedical Compliance

Every material had to be biocompatible and suitable for advanced tissue engineering applications.

Biomedical Compliance

Every material had to be biocompatible and suitable for advanced tissue engineering applications.

Biomedical Compliance

Every material had to be biocompatible and suitable for advanced tissue engineering applications.

Biomedical Compliance

Every material had to be biocompatible and suitable for advanced tissue engineering applications.

Manufacturability

The final design had to be producible within the client's existing manufacturing capabilities and strict size constraints.

Manufacturability

The final design had to be producible within the client's existing manufacturing capabilities and strict size constraints.

Manufacturability

The final design had to be producible within the client's existing manufacturing capabilities and strict size constraints.

Manufacturability

The final design had to be producible within the client's existing manufacturing capabilities and strict size constraints.

Manufacturability

The final design had to be producible within the client's existing manufacturing capabilities and strict size constraints.

Bioprinting the Future of Bone Repair

Our client was developing a next-generation bioprinter designed to produce complex, biocompatible tissue constructs. They had a strong concept but needed help transforming it into a fully engineered, manufacturable product—one that would be both high-performance for advanced biomedical work and visually stunning to inspire confidence among researchers, end-users, and investors. The challenge lay in balancing three critical elements: precision engineering, biomedical compliance, and high-end industrial design—a rare combination that demanded deep expertise across multiple disciplines.

Bioprinting the Future of Bone Repair

Our client was developing a next-generation bioprinter designed to produce complex, biocompatible tissue constructs. They had a strong concept but needed help transforming it into a fully engineered, manufacturable product—one that would be both high-performance for advanced biomedical work and visually stunning to inspire confidence among researchers, end-users, and investors. The challenge lay in balancing three critical elements: precision engineering, biomedical compliance, and high-end industrial design—a rare combination that demanded deep expertise across multiple disciplines.

Our Approach

Our Approach

Defining the Core

Defining the Core

Through structured calls, we worked with the client’s team to define the non-negotiable functional requirements. Early collaboration with their manufacturing partner ensured every design decision was grounded in practical feasibility.

Biomedical Compliance

Biomedical Compliance

Our industrial designers and mechanical engineers worked side-by-side to develop 10 distinct design concepts. After the client selected two preferred options, we began the intensive process of detailed engineering.

Overcoming the Obstacle & Future-Proofing the Design

Overcoming the Obstacle & Future-Proofing the Design

The biggest challenge was fitting all the internal components into a compact chassis without sacrificing performance or maintenance access. The breakthrough came when we developed a custom internal support framework that maximized space while maintaining structural rigidity and a clean, modern exterior. Then to go beyond the initial request, we introduced a modular design approach. This allows for future upgrades to the robotic arm or ultrasound head without a complete redesign, turning the bioprinter into a long-term, adaptable platform.

Our Approach
Defining the Core

Through structured calls, we worked with the client’s team to define the non-negotiable functional requirements. Early collaboration with their manufacturing partner ensured every design decision was grounded in practical feasibility.

Biomedical Compliance

Our industrial designers and mechanical engineers worked side-by-side to develop 10 distinct design concepts. After the client selected two preferred options, we began the intensive process of detailed engineering.

Overcoming the Obstacle & Future-Proofing the Design

The biggest challenge was fitting all the internal components into a compact chassis without sacrificing performance or maintenance access. The breakthrough came when we developed a custom internal support framework that maximized space while maintaining structural rigidity and a clean, modern exterior. Then to go beyond the initial request, we introduced a modular design approach. This allows for future upgrades to the robotic arm or ultrasound head without a complete redesign, turning the bioprinter into a long-term, adaptable platform.

The Solution:

The Solution:
The Solution:

We delivered a complete design package for a compact, modular, and production-ready bioprinter, including manufacturing drawings, material specifications, and assembly details.

  • Manufacturability First: Designed from the ground up to be fabricated with the client’s current production capabilities.

  • Precision Engineered: A custom internal framework ensures the dimensional accuracy and stability required for reliable, repeatable performance.

  • Biocompatible Materials: All components and material choices were vetted to ensure compliance for advanced biomedical applications.

  • Modular Framework: Allows for the seamless integration of future technology upgrades, extending the product's lifecycle.

  • Sleek Industrial Design: A high-end, professional look that reflects the cutting-edge technology within and appeals to users and investors alike.


Result & Takeaway:

Our work provided the client with a production-ready design that was successfully manufactured and integrated into their functional prototype. This polished, professional device became a cornerstone for their investor presentations and product pitches, positioning them at the forefront of advanced tissue engineering tools.

Our Key Takeaway:

This project reinforced the critical importance of integrating manufacturability into the design process from day one. By balancing ambitious design with practical execution, we minimized redesign cycles, accelerated delivery, and created a product that was ready for both the lab and the market.

Testimonials

Jia-En Danny Chen

London, UK

Seamless Experience with Outstanding Results

Working with Designing Alley was easy and professional. We needed a platform where users could upload their 3D files, customize them, and get them delivered — and the team nailed it. They really understood what we were aiming for, stayed responsive, and the end result is exactly what we needed. Highly recommended!

Amine Kahlaoui

Zurich, Switzerland

A True Partnership Fueled by Creativity and Care

Working with Designing Alley felt like having a true partner. They listened, asked the right questions, and built Slice of Lime with care and creativity. It’s rare to find a team that’s both talented and genuinely invested.

Akash Porwal

Delhi, India

Brilliant Minds Behind Our IoT Breakthrough

Designing Alley truly nailed it with our  IoT project. Their brilliant PCB designs and smart project architecture brought our idea to life in a way we couldn't have imagined. We are lucky to have them as our partners in this journey.

Testimonials

Jia-En Danny Chen

London, UK

Seamless Experience with Outstanding Results

Working with Designing Alley was easy and professional. We needed a platform where users could upload their 3D files, customize them, and get them delivered — and the team nailed it. They really understood what we were aiming for, stayed responsive, and the end result is exactly what we needed. Highly recommended!

Amine Kahlaoui

Zurich, Switzerland

A True Partnership Fueled by Creativity and Care

Working with Designing Alley felt like having a true partner. They listened, asked the right questions, and built Slice of Lime with care and creativity. It’s rare to find a team that’s both talented and genuinely invested.

Akash Porwal

Delhi, India

Brilliant Minds Behind Our IoT Breakthrough

Designing Alley truly nailed it with our  IoT project. Their brilliant PCB designs and smart project architecture brought our idea to life in a way we couldn't have imagined. We are lucky to have them as our partners in this journey.

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