Precision, Speed, and Scalability in Medical Manufacturing
A custom medical laser system has transformed production efficiency for PocDoc — an innovator in digital diagnostics and lateral flow cholesterol tests. As demand grew, their off-the-shelf flatbed laser system couldn’t keep up. Each sheet took 45 minutes to process — creating a major bottleneck.
To address this, Thinklaser engineered and delivered a bespoke CO₂ galvo laser system tailored to PocDoc’s medical production workflow. Now, the same process takes less than a minute with dramatically improved speed, consistency, and reliability.
The Challenge: Off-the-Shelf Wasn’t Cutting It
Using a flatbed laser system to ablate and cut intricate, high-tolerance medical components, PocDoc encountered growing issues:
- Inconsistent output
- Extended processing times
- System reliability concerns
“As a rapidly scaling business, we encountered growing challenges with our off-the-shelf laser machine, particularly in terms of accuracy, consistency, reliability and processing time. These limitations quickly became a significant bottleneck within our production workflow.” — Andy Butcher, Operations Manager
The system couldn’t meet PocDoc’s scaling and performance goals. A more intelligent, repeatable, and faster solution was needed.
The Solution: A Custom CO₂ Galvo Laser System Built for Medical Production
Thinklaser designed a precision laser system specifically for PocDoc’s lateral flow test production. Key custom features include:
⚙️ A high-performance galvo-driven CO₂ laser for rapid, accurate ablation
🧲 A pneumatic jigging system for repeatable material placement
🧱 Mechanical back stops for alignment
🔒 Integrated laser safety compliance with medical device standards
🧰 Simplified maintenance access
The result is a bespoke medical laser cutting solution optimised for speed, safety, and precision.
“We engaged Thinklaser with a clear objective to design, build, and deliver a bespoke laser system that would not only address these issues but significantly increase our throughput, with the added goals of easy maintenance and adherence to stringent safety standards.” — Andy Butcher, Operations Manager
The Results: A 95% Reduction in Processing Time
Once installed, PocDoc’s new laser processing system delivered immediate and measurable impact:
⏱ Processing time reduced from 45 minutes to under 1 minute
🎯 Consistent, repeatable ablation and cutting
⚡ Up to 30x faster throughput
🛡️ Enhanced safety and reliability
🧽 Streamlined maintenance protocols
“The new system enables highly consistent ablation at speeds up to 30 times faster than our previous setup.” — Lukasz Dziobek, Production Manager
“A key improvement is the simplified maintenance — replacing complex mirror alignment and coolant level checks, with a straightforward wipe-clean-and-go approach.” — Lukasz Dziobek, Production Manager
“The results have been impressive. Thinklaser has delivered a well-engineered, reliable, and user-friendly system that prioritises both safety and performance. Most importantly, we are now achieving a consistent output and have reduced our laser processing time by over 95%, transforming a previously constrained stage of our production line.” — Andy Butcher, Operations Manager
Beyond Medical: Thinklaser’s Custom Laser Systems Across Industries
Thinklaser’s custom laser expertise isn’t limited to medical applications. The company has also engineered advanced systems for:
🚗 Automotive part marking and surface treatments
🛰️ Aerospace and space R&D for materials processing and component identification
💻 Semiconductor wafer marking and microprocessing
🎯 Defence and military applications including coded asset marking
📱 Electronics manufacturing for PCB etching and housing marking
The short video below features a galvo fibre laser system cleaning the surface of a coin. In contrast, the PocDoc application utilised a CO₂ laser — offering a far more delicate and precise solution. This demonstrates the versatility of the Thinklaser Lightwriter platform.
With a track record across highly regulated and high-precision sectors, Thinklaser delivers tailored laser solutions built for reliability, compliance, and performance.
The Takeaway: Bespoke Laser Engineering That Delivers
Thinklaser’s collaboration with PocDoc highlights the power of a custom medical laser system. Off-the-shelf equipment often falls short in demanding production environments. A tailored approach enables:
🚀 Faster processing speeds
🎯 Improved repeatability and accuracy
🧪 Optimised compatibility with specialist materials
🔐 Full compliance with medical safety standards
Whether it’s laser ablation, material marking, or high-precision cutting, a custom-built solution can unlock significant production gains.
Frequently Asked Questions (FAQ)
Why use a CO₂ galvo laser instead of a flatbed for medical manufacturing?
Galvo lasers use mirror-based beam steering, enabling much faster and more precise processing — ideal for high-tolerance, high-volume medical device production.
Can Thinklaser build custom systems for other healthcare applications?
Yes. Thinklaser specialises in designing and delivering bespoke laser systems for a wide range of industries, including medical diagnostics, pharmaceuticals, and biotech.
Why is precision so important in lateral flow tests?
Inaccurate cuts or ablations can impact fluid dynamics and test accuracy, so precision and repeatability are essential.
Do custom laser systems require more upkeep?
Not with Thinklaser’s design. PocDoc’s new system is engineered for easy cleaning and minimal maintenance, reducing downtime and operator intervention.
What safety features are included in a custom medical laser system?
Thinklaser incorporates multiple safety measures including interlocked enclosures, automatic laser shutoff, and compliance with medical device laser safety standards (such as IEC 60825-1). These features ensure operator safety and regulatory adherence.
How scalable is a bespoke laser solution?
Custom laser systems are engineered with scalability in mind. Thinklaser’s solution for PocDoc is modular, allowing for easy adaptation as production volumes increase — ideal for growing businesses in medical diagnostics.
How long does it take to build a custom laser system?
Depending on complexity, most bespoke laser systems take 8 to 16 weeks from concept to delivery. This includes consultation, design, prototyping, testing, and installation.
What makes galvo lasers more efficient than flatbeds?
Galvo systems move the laser beam using fast-moving mirrors instead of moving the workpiece. This reduces motion lag, increases speed, and enables high-precision ablation — especially useful for delicate or detailed components in medical production.
How is a custom medical laser system validated before delivery?
Each bespoke medical laser system from Thinklaser undergoes rigorous in-house testing and quality assurance before deployment. This includes precision calibration, functional testing with client-specific materials, and verification against safety and performance benchmarks. Validation ensures the system performs reliably in the end-use medical manufacturing environment.
Thinklaser: Your Partner in Custom Laser Systems
If you’re facing limitations with your current laser process — in medical, electronics, or advanced manufacturing — Thinklaser can help.
💡 We build intelligent, custom laser systems designed to meet your exact needs for speed, safety, and scalability.
👉 Contact Thinklaser to start your project today.
