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CASE STUDY · MEDICAL PACKAGING · INDUSTRIAL DESIGN

Ultraschall: one packaging system for a complete colposcope range

Colposcope packaging and IntegraScope V2 development

How can one package transport different medical devices? At A1Pack, we designed packaging for Ekhoson colposcopes that holds the complete device, its components and accessories. The same system serves the D3 and S3 models and is also planned for the new IntegraScope V2.

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PRODUCT DEVELOPMENT CASE STUDY · SPECIAL SOLUTIONS

One technical packaging system for different medical devices

A1Pack developed colposcope packaging to transport, organize and protect the complete equipment set. The design serves the Ekhoson D3 and S3 models supplied by Ultraschall and is also planned for the new IntegraScope V2. A single structural solution, with internal cardboard supports and a handle, limits the number of cutting dies and supports batches of 100 to 500 units. The project combines industrial design, microflute corrugated cardboard and local production at Taller Protegido Los Tilos.

Open Ultraschall packaging with colposcope components organized inside

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01 · The challenge: transporting a complete medical device

Ultraschall needed packaging that could contain a colposcope and all the components required for transport and use. The wheeled base, column, optical assembly and accessories each needed a defined position. The package also had to be practical to handle and viable in small quantities. We approached protection, organization and manufacturing as parts of the same system.

  • Goal: contain and transport the complete colposcope with its components and accessories.
  • Design requirements: protect parts with different geometries, organize the contents and simplify packaging assembly.
  • Production requirement: deliver a functional solution for batches of 100 to 500 units.

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02 · Packaging for the D3, S3 and IntegraScope V2 models

The main decision was to create one technical packaging system for different colposcopes in the Ekhoson range. The D3 and S3 models share a structural solution that is also intended for the new IntegraScope V2. Internal cardboard components separate, support and hold the device parts, while an integrated handle facilitates transport. A common architecture supports repeatable manufacturing across the product family.

  • Shared system: one packaging format adaptable to different Ekhoson colposcope models.
  • Internal supports: supports, dividers and cutouts that keep the equipment parts organized.
  • Handling and transport: the device and accessories travel together in one package with a handle.
Ultraschall box with colposcope parts and internal cardboard dividers
Open Ultraschall packaging holding a wheeled base and colposcope components

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03 · Packaging engineering: fewer dies and efficient construction

To make short-run colposcope packaging viable, we focused on structural efficiency. Using E-flute corrugated cardboard, we developed supports, openings, folds and closures with a limited number of cutting dies. This made effective use of the material and kept the production process manageable. Single-color screen printing completes the functional design. The system can be produced and replenished in quantities suited to demand for specialized medical equipment.

  • Material and printing: E-flute corrugated cardboard with single-color screen printing on one side.
  • Optimization: folds, cutouts, closures and internal supports designed around a small number of dies.
  • Short runs: a technical solution for batches of 100 to 500 units and periodic replenishment.

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04 · Manufacturing at Los Tilos and development toward IntegraScope V2

The packaging is manufactured at Taller Protegido Los Tilos, a sheltered workshop in La Plata. This collaboration supports small-scale production and inclusive employment. The relationship with Ultraschall also expanded into industrial development of the new IntegraScope V2 digital colposcope. Based on the Ekhoson D4, the housing redesign considers assembly, fasteners, connections, access and tolerances to improve manufacturability. This work is still in development; the final product has not yet been validated. IntegraScope V2 is planned to use the same packaging system as the existing models.

  • Manufacturing: short-run colposcope packaging produced at Taller Protegido Los Tilos.
  • Standardization: one package for the D3, S3 and future IntegraScope V2.
  • Project continuity: housing redesign for the new digital colposcope with manufacturing and assembly requirements in mind.
Ultraschall digital colposcope with optical head and support

Need technical packaging for a device or a special product?
At A1Pack, we develop special solutions from structural design and internal supports through short-run manufacturing. Tell us what equipment you need to protect, transport or manufacture.

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Technical design also improves how a product is manufactured.

The Ultraschall project shows how colposcope packaging can address protection and production together. By standardizing packaging across different models, A1Pack optimized material use, reduced tooling requirements and simplified small-scale replenishment. The ongoing IntegraScope V2 work connects packaging design with development of the device itself, coordinating structure, product and process.