RockStar DL01

Automating MDI testing

Launched at the Respiratory Drug Delivery (RDD) 2025 Tradeshow in Lisbon

Problem
Lewis Jonsen Solutions envisioned a solution to automate the waste shot firing process in MDI testing - the most repetitive and fatigue-inducing part of the workflow - the client brought the concept to Relay Industries to commercialise. The aim was simple: reduce error, increase consistency, and free scientists to focus on the shots that matter.

Process
Relay Industries refined the client’s initial proof-of-concept into a robust, manufacturable product through a comprehensive design and engineering effort. This included industrial design, CMF (colour, material, finish) development, and the design of a custom membrane keypad. The mechanical architecture was developed in sheet metal with a strong emphasis on design for manufacture. Throughout the process, we sourced and coordinated with UK-based manufacturers to ensure quality and streamlined production.

Outcome
A focused, smart automation system built specifically for MDI waste shot testing - enhancing efficiency, repeatability, and reliability in high-volume lab settings.

• Automates only the waste shots — where human error is highest
• Removes manual shake/fire variability
• Programmable for precise and repeatable shake angles, timing, and valve hold duration
• Reduces scientist fatigue and batch failure risk
• Enables 4–5 lab scientists to tag-team usage, optimising workflow and boosting throughput
• Frees lab teams to focus on the essential measured shots

Client
Lewis Jonsen Solutions

Services
Industrial Design & Development
Mechanical Design (Sheet Metal)
Prototyping
Membrane Keypad Design
Embedded Electronics Integration
Design for Manufacture
Product Visualisations & Blender Animations
UK Manufacturer Sourcing
Medical Device Design