The Challenge: A Critical Casting with Clinical Standards

The heart of GCX’s Fetal Monitoring Cart lies in its 20-pound gravity diecast base and connector assembly. This component does more than support the workstation – it houses sensitive electronics, routes cables, and provides mounting points for articulating arms to hold vital display monitors.

Here are just a few of the many challenges of casting this part:

• Structural Demands: Wall thickness of255 inches exceeded the limits of high-pressure diecasting, requiring gravity casting for its ability to deliver on both strength and stability.
• Complex Geometry: The fetal cart workstation base integrates channels for cable concealment, in-base storage for CPUs or UPS units, and attachment points for modular accessories, including monitors and barcode scanners.
• Flawless Finish: Amedical-gradewhite, powder-coated surfaceenhances infection control and delivers aesthetic appeal in clinical environments.
• Documentation Gaps: Original drawings lacked tolerances, finish specifications, and color requirements, creating uncertainty for new production.
• Supply Chain Pressure: GCX had relied on one overseas supplier for decades, so they were ready to diversify their supplier base and secure a more U.S.-aligned manufacturing strategy.

Solution: Engineering Precision for Medical Compliance

Solving GCX’s challenge meant more than merely casting a part as usual. Instead, it required MES to replicate and document a complex design, perfect a medical-grade finish, and ensure full compliance to standards and specifications.

MES delivered on all fronts by applying our gravity diecasting experience and engineering expertise, advanced paint-matching technology, and robust quality documentation to meet the demands of a clinical environment.

Engineering Expertise

• Assisted GCX in revising incomplete or outdated drawings to reflect requirements, tolerances, and aesthetic standards.
• Supported process improvements to meet stringent surface finish requirements, addressing challenges posed by thick-wall geometry and curved part profiles.
• Applied real-time problem-solving to adapt tooling and manufacturing workflows for both performance and aesthetics.

Gravity Diecasting Experience

• Produced a single-piece aluminum alloy casting weighing 20 lbs., delivering strength and dimensional repeatability.
• Partnered with a vetted ISO-compliant supplier in India, experienced in precision casting for high-stakes industries.

Custom Powder Coat Perfection

• Developed a proprietary white finish by trialing multiple powder coat suppliers.
• Applied spectrophotometer analysis to control color consistency with L*a*b* values and maintain Delta E ≤ 1.5.
• Implemented contamination controls, including paint line purging, as well as physical separation of white vs dark color operations in-plant to achieve a virtually flawless, medical-grade finish.

Quality System Development

• Collaborated with GCX to resolve ambiguous specifications and update drawings.
• Created paint inspection criteria and color requirement tables that GCX had never documented before.
• Ensured adherence to ISO and FDA-registered quality processes, which are crucial in medical device manufacturing. 

Supply Chain Resilience

• Added a second qualified source outside China/Taiwan, reducing risk, minimizing tariff impacts, and improving lead times.
• Supported GCX’s plans to move final assembly internally, enabling them to provide their customers with a higher level of of customization.

The Result: A Stronger Solution and More Resilient Supply Chain

When our painted castings ultimately rolled off the line, GCX didn’t just get the parts they needed, they gained the confidence they deserved in their supply chain partner, MES. The new base delivered the strength to handle years of clinical use without flex or fatigue, even under the load of monitors and articulating arms. Its flawless white powder coat was visually appealing and passed every finish inspection.

Beyond the hardware, MES helped GCX close long-standing gaps in documentation, creating a foundation for consistent quality and compliance moving forward. By securing a second qualified supplier outside their traditional region, GCX now has the supply chain resilience to weather global disruptions while also setting the stage for future U.S.-based assembly and greater customization flexibility.