Client Need & Project Overview
When clinicians perform tissue biopsies, the entire sample is typically preserved in a formalin solution. It is also common that during initial processing, the tissue is exhausted, leaving an insufficient quantity of material for secondary molecular testing. Additionally, even if ample material remains, samples stored in formalin are not always compatible with more advanced tests, such as RNA translocation assays or organoid creation. These limitations can leave many patients ineligible for precision medicine or force them to undergo additional biopsies.
Virchow Medical (formerly Corramedical) developed the Crow’s Nest™ Biopsy Catchment System to address these gaps. The system captures dislodged tumor cells that are normally discarded with the biopsy needle, creating a second liquid specimen in addition to the core tissue block. This unfixed liquid sample remains stable at room temperature for extended periods and avoids the formalin-induced damage that can compromise genomic testing. By enabling broader molecular analysis without requiring additional procedures, the system expands access to precision diagnostics and reduces the need for repeat biopsies.
NOVO was approached by Virchow Medical to develop their second-generation Crow’s Nest device. They were confident that the refreshed product would exceed performance requirements and improve the design for high-volume manufacturing.
Key Engineering Challenges & Solutions
| Challenge | NOVO’s Solution |
|---|---|
| Improve part interfaces | Conducted a detailed tolerance analysis; redesigned and simplified sealing interfaces. |
| Increase filter efficiency | Reengineered the product around a single-part filter. Directly micromolded a 350-micron filter into the plastic housing, reducing manufacturing cost and improving flow-through. |
| Material compatibility with saline, cells, and formalin while ensuring drainage | Chose high surface energy (hydrophilic) polymers that supported rapid liquid passage and maintained chemical compatibility with biological samples. |
| Engineering for high-volume production | Redesigned for manufacturability by reducing component count and developing molds optimized for high-volume micromolding, ensuring cost efficiency and consistent quality. |
Technical Innovations & System Design
- Micromolding at Scale – The insert-molded part used in the first-generation device was functional, but it prevented complete fluid transfer and added to cost and manufacturing complexity. The second-generation device leveraged our experience in micromolding to create a one-piece 350-micron filter without flash, leading to major manufacturing and performance improvements.
- Hydrophilic Material Properties – Leveraged comprehensive knowledge of material properties to address surface tension challenges while ensuring chemical compatibility with the sample and solutions. The polymer selected was suitable for micron-level tolerance micromolding, ensuring efficient fluid flow and complete drainage.
- Simplified Assembly – Reduced part count, eliminated gaskets, and increased quality enabling faster, more reliable, and lower-cost production.
These design decisions improved manufacturability while maintaining compliance with sterilization and biocompatibility requirements.
Results & Impact
- Exceeded Performance Targets – Achieved faster, more complete filtration with reduced residual fluid.
- Cost Improvements – Lowered component count, optimized micromolding for high-volume production, and improved overall unit cost.
- Positive Clinical Feedback – Early prototypes received favorable responses from physicians, who confirmed the system’s promise in real-world biopsy settings.
- Path to Market – The product is advancing through production and into clinical trials.
Why NOVO Engineering?
Corramedical was certain that NOVO’s expertise in tolerance analysis, experience with micron-level micromolding, and deep knowledge of material properties was exactly what they needed to deliver the second-generation Crow’s Nest. NOVO not only improved the product’s performance but also created a device ready for commercial scalability.
This project established trust and led to a second engagement, strengthening the client’s confidence in NOVO as a long-term engineering services provider.
Call to Action
Do you face complex design challenges in medical devices or life sciences?
Contact NOVO today to learn how our expertise in precision engineering, micromolding, and designing for high-volume manufacturing can help bring your innovation to market.
