Mohamed Elwalid Fadul
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Case study 01

Aorta Compressor Prototype

QuAC is a proof-of-concept device developed to automate external aortic compression during postpartum haemorrhage. The four-month academic project combined input from healthcare professionals, mechanical product development, a custom linear actuator, wireless control and full-system prototyping.

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Discipline
PRODUCT DEVELOPMENT / MECHATRONICS / PROTOTYPING
Course
TMM4121 — Product Development
Project type
academic
Period
Spring 2025 · 4 months
Evidence
Control code + Technical report
Team
13 mechanical engineering students
My role
Mechatronics
Complete QuAC student prototype during a documented demonstration
Complete prototype during the documented student demonstration. This was a proof-of-concept test, not a clinical evaluation.
Close-up of the ESP32, L298N driver, motor and custom actuator assembly
Integrated actuator assembly with the ESP32 controller, L298N motor driver, geared DC motor and exposed prototype wiring.
Completed two-button handheld controller for the QuAC prototype
Completed handheld controller used to transmit upward and downward actuator commands over ESP-NOW.
CAD assembly of the QuAC compression system without its cover
Team-developed CAD assembly showing the actuator, electronics packaging and compression interface.
CAD close-up of the custom leadscrew actuator mechanism
Team-developed detail of the custom leadscrew, gearing and motor-bracket arrangement.
Fusion 360 von Mises stress result for the curved QuAC baseplate
Fusion 360 stress result produced by the mechanical design and analysis sub-team.
Wireless actuator handheld remote wiring diagram
Remote-controller wiring with ESP32 and active-low direction buttons.
Linear actuator controller wiring diagram
Actuator-side wiring between the ESP32, L298N driver and DC gearmotor.
Linear actuator receiver control-flow diagram
Receiver logic for interpreting commands and controlling actuator direction.
Wireless handheld remote control-flow diagram
Remote-controller logic for reading active-low button inputs and transmitting commands over ESP-NOW.

01 / Engineering challenge

The system behind the project

The concept had to translate a clinically informed target into a controllable mechanical system: approximately 40 kg of compression force, rapid setup, remote operation and compatibility with different hospital beds. This was a student proof of concept, not a certified medical device, so safety limitations and unverified clinical use must remain explicit.

02 / My responsibility

What I personally worked on

My assigned responsibility in the two-person mechatronics sub-team was electronic components, programming and implementation in the physical product. I worked on the two-ESP32 wireless architecture, ESP-NOW communication between the handheld controller and motor unit, button-based direction control, motor-driver integration and full-system testing with the mechanical and production teams.

Engineering focus

  • — Wireless actuator control
  • — Electronics integration
  • — Prototype manufacturing
  • — Full-system testing

Tools and methods

ESP32ESP-NOWC/C++Fusion 360Prototyping

03 / Design and implementation

From concept to working system

  1. 01

    Translate stakeholder input into prototype requirements, including a target compression force above 40 kg and remote operation.

  2. 02

    Develop ESP-NOW communication between two ESP32 nodes, progressing from basic value transfer to button commands for actuator direction.

  3. 03

    Integrate the 12 V geared DC motor, L298N driver, battery supply and electronics into the custom leadscrew actuator.

  4. 04

    Test the complete assembly, troubleshoot motor-driver heating and controller issues, and verify maximum force using a scale-based test setup.

04 / Testing and outcome

What the work demonstrated

The integrated prototype achieved a highest measured force of 45.8 kg, exceeding the 40 kg prototype requirement by 5.8 kg (14.5%). The remote ESP-NOW controller simplified operation, but testing also exposed important limitations: motor-driver overheating, no force sensor or closed-loop regulation, no dedicated emergency stop and no end-of-travel protection. These results support the prototype objective while showing that substantial safety engineering and verification would be required before any clinical application.

05 / Next iteration

How I would develop it further

  • 1Add force sensing and closed-loop force regulation with defined safe limits
  • 2Implement a mechanical emergency release, electrical emergency stop and end-of-travel protection
  • 3Replace the L298N with a more efficient motor driver and consolidate the power supply
  • 4Perform structured verification, risk analysis and supervised human-factors evaluation
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