Inflatable Bed Cover

Proficiently develop a reliable, and functional inflatable bed cover for a therapeutics business that focuses on advanced specialty beds and support surfaces. The cover requires a specified leak rate, which was to be accomplished through a precise perforation.

It was unknown which material would be best, and what thickness, to achieve all the regulatory specifications. Additionally, there was uncertainty regarding how to perforate the material (i.e. which perforator to use, how big perforations should be, etc). This was particularly complex because the client had previously used a perforator that went out of business, and no perforation specifications existed that could be transferred, requiring TPI to determine specifications through testing.

In order to meet the technical requirements of which material would be best and meeting the regulatory requirements as well as how to perforate the material, TPI carried out a systematic experimental approach. We achieved this by creating many prototypes through an intricate design and manufacturing procedure. Prior to executing this process, TPI created and reviewed the requirements alongside the client. TPI explored and tested several perforation sizes, patterns, puck sizes, locations, and weld settings. Additionally, test fixtures were acquired and evaluated according to test requirements, and multiple prototype samples were provided to customers for user feedback.