In short
- The challenge: a medical-device manufacturer calibrated its IPL (intense pulsed light) and laser systems by hand. The process was slow, operator-dependent and hard to trace.
- The solution: IZAK Scientific designed a complete automated tester: a test jig with a precision power meter, a secure handpiece coupling and software that talks to the console and the handpiece.
- The process: identify the handpiece, run a burn-in test, calibrate every operating state, write the coefficients into the handpiece memory, then verify the fluence of every state with an automatic pass/fail.
- The result: about one hour of operator time saved per unit, higher production yield, consistent calibration and digital, signed reports uploaded to the customer’s cloud database.
IZAK Scientific partnered with a medical-device company to build a customised automation solution for its IPL (intense pulsed light) and laser machines. The goals were to streamline production, reduce human error, save time and improve precision and accuracy, and in doing so to raise production yield and strengthen quality control.
The system was built on radiometry calculations for robustness and combines precision hardware with intelligent automation software. It changed the way the company calibrates and checks its devices, and it saves time and money on the production line.
The challenge: manual calibration of IPL and laser handpieces
Every handpiece was calibrated by hand, state by state. The work was tedious and took operator time on every unit.
Human intervention adds variability. For a medical device, calibration consistency is a matter of quality and patient safety.
Results had to be documented, signed and stored so they could be traced and audited for compliance.
The solution: a complete automated tester
IZAK Scientific designed and built a complete tester system, with both hardware and software:
- Hardware: a test jig integrated with a precision power meter, and a mechanism that couples the device’s handpiece securely to the measurement system.
- Software: an application that communicates with all the hardware, from the machine’s console to the handpiece.
The result is an automated, hands-free test environment that minimises human error and variability:
- Handpiece identificationThe application recognises the model of the attached handpiece and asks the operator to confirm that it is the correct device.
- Automatic runAfter confirmation everything runs automatically, which saves about one hour of operator time.
- Burn-in testA short burn-in warms up the handpiece and verifies that it operates stably.
- Self-calibrationOnce stability is confirmed, calibration starts. It is much faster and more precise than the manual process.
How the calibration works
The application drives the machine through a series of predefined states, each corresponding to a different condition of the electronic driver. At each state the system measures the optical power and other radiometric and optical values precisely.
In the background the software calculates the calibration coefficients. The coefficients are determined with calibrated measurement devices selected to meet industry standards. One coefficient is calculated for each operating state and written into the handpiece memory. This ties the calibration data to the hardware itself, so the handpiece performs consistently and stays compliant wherever it is used.
Verification and quality assurance
After calibration the system runs a comprehensive verification:
- The machine is operated at all available states using the new coefficients.
- At each state the optical power and other values are measured again, and the corresponding fluence (energy per unit area, J/cm²) is calculated.
- The results are compared with the device’s required specifications to decide whether the calibration succeeded or needs adjustment.
- An automatic pass/fail result is generated for each state, based on whether the fluence falls within the acceptable limits.
This real-time assessment finds problems quickly and allows immediate troubleshooting. The tool below shows the same check for a single state.
Fluence and pass/fail check for one state
Enter the measured output of one operating state and the spot size of the handpiece. The tool calculates the fluence, compares it with the specification and shows the correction factor that would bring the state to its nominal value.
Fluence = pulse energy ÷ spot area. With average power, pulse energy = power ÷ repetition rate. The correction factor is nominal ÷ measured fluence: the ratio a calibration coefficient applies to bring the state to its nominal output. A simple model for illustration; your device’s calibration algorithm and limits come from its own specification.
Watch: automated calibration and verification
Benefits of automation
IZAK Scientific delivered an end-to-end solution, from the tester design to the software that communicates with all the hardware. The software calibrates with accuracy and consistency and significantly increased production yield.
The automated system replaced a tedious manual process and saves about one hour of operator time per handpiece.
Removing human intervention improves reliability and repeatability, which is essential for device quality and safety.
All documentation is digital and signed by the operator. Reports and measurement results are uploaded to the company’s cloud database for traceability and compliance.
The customer can correlate machine-operation reports from the field with the final test reports, for analytics and statistical insight.
Higher production throughput, with a precision that would be hard to match manually.
Automated verification ensures that every handpiece meets strict quality standards before it leaves the line.
Conclusion
This collaboration shows the value of bringing automation into a production environment. By automating calibration and verification of its IPL and laser systems, the client achieved faster production, lower costs and better product quality.
The same approach applies to other light-based devices: see how we work with medical-device companies, read about applications for pulsed flash lamps, the light source behind IPL, and the basics of radiometry and photometry that the calibration is built on. Our work is carried out under an ISO 9001 certified quality system.
Related products for optical power and pulse measurement: the Power Meter Module, the TriBeam Precision laser inspection software and the Multi-Channel Spectro-Radiometer. For custom test systems, see our design and development service.
Frequently asked questions
QHow are IPL and laser medical devices calibrated?
QHow is fluence calculated?
QCan IZAK build an automated tester for our device?
Tzachi Sabati
CEO, IZAK Scientific
Physicist specializing in photonics and quantum technologies, with deep expertise in quantum sensors and advanced optical systems. Leads the Advanced Quantum Lab course at the Technion, bridging academic excellence with industry innovation. At IZAK Scientific, provides cutting-edge photonics-based solutions, developing customized inspection and sensing systems for R&D and production. Passionate about advancing quantum sensing applications and integrating novel technologies to meet industry needs.
