Convergence Medical Sciences – Valence InVent Xtend
Background
During the early stages of the COVID pandemic, ventilator shortages were a global concern. Many units were not immediately deployable, as they required extraction from storage, calibration, and testing prior to use. Moreover, ventilator sharing—an ad hoc solution to the shortage—was often implemented in ways that proved both inefficient and potentially unsafe.
The Challenge
Dr. Steven Roy, a skilled respiratory therapist, identified an opportunity to safely manage ventilator sharing by using a manifold with Positive End-Expiratory Pressure (PEEP) valves. This setup would enable individualized pressure control for each patient without risking cross-contamination. Dr. Roy initially built a PVC prototype that demonstrated the concept, but he needed engineering and manufacturing expertise to turn it into a device suitable for high-precision, ISO-compliant medical use.
Solution
Partnering closely with Dr. Roy, we brainstormed design ideas and initially created a version optimized for powder bed additive manufacturing, specifically Multi Jet Fusion (MJF) with vapor-smoothing post-processing. This early design, which resembled the final production version, won a 2022 Red Dot Design Award. The additive manufacturing phase allowed for rapid iterations, solving critical challenges in meeting tolerances and ensuring reliable seals while balancing aesthetic appeal with functionality.
As Convergence Medical Sciences progressed, I adapted the design for injection molding, enabling scalable, cost-efficient production. Working in collaboration with the injection molder, I adjusted the draft angles, surface markings, and other features to ensure compatibility with their equipment and maintain the high standards required for healthcare applications.
Impact
The initial additive-manufactured design proved invaluable in achieving a healthcare-ready device with rapid iteration, though it presented challenges such as powder residue and imperfect surface finishes for tight seals. Injection molding resolved these issues, offering a consistent, cleanable, and cost-effective solution ideal for the medical environment. The final version is suitable for autoclaving and meets ISO standards, making it reliable and easy to manufacture at scale.
Current Status
With Health Canada approval in place, Convergence Medical Sciences is now working toward FDA approval, broadening their market reach and expanding their product line to support healthcare needs globally.
Convergence was recently named one of Calgary’s Top 50 Most Scalable Companies by Scale Up Canada. It's an impressive and very well deserved recognition of their impact and growth trajectory.
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