Designing the next generation of people-screening systems
Services
- Design engineering
- Simulation and analysis
- Ergonomic design
- Rapid prototyping
- Embedded systems development
- Innovation workshops
- Functional prototyping
- Concept generation
- Product strategy development
Sector
- industrial
Client
Thruvision’s passive terahertz people-screening technology is uniquely capable of detecting metallic and non-metallic threats in real-time. This includes weapons, explosives and contraband, hidden under clothing at distances up to 10 metres, and was designed to speed up security screening and eliminate the need for physical searches. Spun out from the prestigious Rutherford Appleton Labs (at Harwell Science and Innovation Campus, Oxfordshire), Thruvision has successfully commercialised $50 million of research investment, with products now used in 30 countries worldwide to improve border security, detect and prevent retail distribution theft, and enhance venue safety.
Thruvision saw the opportunity to develop a next-generation screening system, which needed to reflect a new corporate identity along with improved thermal stability, enhanced aesthetics and ergonomics and optimised manufacturability. The design both needed to complement its intended environment while better reflecting the value of the cutting-edge technology contained within. Our strong track record working with Thruvision on earlier products positioned OPD as the ideal partner for this project.
We guided Thruvision through a structured Phase 0 workshop in their offices. This identified a number of key opportunities for the product while establishing which aspects of the design were critical and needed to be maintained or optimised. We worked closely with Thruvision’s in-house team—Thruvision working from the inside out and OPD from the outside in.The collaborative nature of this was crucial, and it meant both teams were totally aligned on the right project direction from the outset.
Bringing ideas to life
Levaraging the latest augmented reality (AR) technology meant that everyone involved could get an immersive, real time look at all of the design proposals – as if the finished product was right in front of them. As well as really helping everyone get a true feeling for the design, it meant faster decisions could be made on CMF (colour, material, finish), saving time and costs on the actual physical prototypes.
Putting users at the centre of the design
The unit needed to offer ultimate flexibility in how it was used, regardless of how it was configured. We explored real-world user interactions and developed a range of usage scenarios during the workshop, which meant that this could be built into the design from the start.
Making sure the outside reflects the inside
Previously, the unit was bulky with disconnected modules, totally underselling the cutting-edge technology contained within. Designing a sleek, unified and high-end unit meant that it was just as well suited to a reception area as it was a warehouse. The ID team held collaborative design reviews with Thruvision, considering CMF to create a stylised finish and refining sketches and renders based on their input. We selected materials for their durability, while making sure they were manufacturable in line with the design requirements. Sheet metal and pressure formed plastic panels enabled us to achieve a premium look while maintaining cost-effectiveness.
The new 81 series launched on schedule, driven by the strong market demand for the updated design.
Simplifying the supply chain and optimising the bill-of-materials costs, ensured production was efficient and scalable. Using a modular design means that a wide range of product variants can be made from a standardised kit of parts, reducing the need for excess stock while ensuring future-proofed flexibility for further iterations and special customer requests.
Visually, the understated yet high-tech aesthetic respects the advanced technology contained within while blending seamlessly into a whole range of environments. Combining innovation, efficiency, strategy, and collaborative teamwork resulted in a sleek, high-performance, and scalable product that meets the demands of today while preparing for future growth.
A huge thank you to the OPD team for their hard work on the 81 Series. The results are fantastic, and the feedback has been overwhelmingly positive—everyone loves it! I look forward to continuing our collaboration on future Thruvision products and bringing even more innovative solutions to life together.
