Higo Sense: from concept to a device physicians trust, in under a year
A proper medical exam still means the same thing: a waiting room, a 15 minute appointment, a chunk of your day gone. Higo Sense compresses nine clinical examinations, throat, ears, skin, heart, lungs, and more, into one handheld device. Run the full exam in minutes. Send the results straight to a physician.
Turning a new medical device category into a certified, manufacturable product
This is a genuinely new category of device. Built to be used safely at home, by people with no medical training. Together with HigoSense and ManGo Product Design, we took it from concept to a certified, market ready product. Here's what that took:
- Nine exams in one device: throat, ears, skin, and audio recordings of heart, lungs, and abdomen
- Cloud-connected: results reach a physician for review in as little as four minutes
- Built for people who aren't medical professionals to use correctly, every time
Nine medical functions in one lightweight device leaves no room for error. Every one of the 60+ parts across 13 molds had to fit together perfectly. The device still had to assemble quickly, perform consistently at a medical grade, and hit a one year certification deadline.
Production Heroes managed manufacturing of all hardware components (electronics and assembly handled separately), including:
Manufacturing 13 separate injection molds and 60+ custom parts
Precision processes: injection molding, metal stamping, milling, thermoshaping, and lightguide production
Two-component rubber molding for a fully watertight seal
End-to-end coordination across manufacturing in Europe and Asia
Medical grade wasn't nice to have. It was the whole point:
Certified biocompatible plastics (Novodur), aluminum, stainless steel, TPE, and ABS
Watertight sealing for safe, hygienic daily use
94% match rate with in-person examination results
75% faster consultations (4 minutes vs. 15) and 97% physician satisfaction
Now used by telemedicine platforms and health systems across Europe and beyond, including MedEA (Italy) and Guardian Eye/AVA (South Africa)
Are you the next hero?
Send us your drawings. An engineer will tell you whether it can be made, what it costs per unit, and how fast it can reach your market.