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  • Three quarters front view of the entire Orthoralix 8500 unit
  • Side view of the C846 in its recumbent cycle configuration
  • Three quarters front view of the Touch Master Game Center
  • Three quarters front view of the final production version of the Advantx x-ray table
  • Three quarters rear view of the life circuit system
  • Three quarters rear view of the life circuit system
  • Three quarters overhead view of the pro model court reporter molded in textured gray plastic
Cesaroni Design is a SPE Thermoforming Conference Award winner

Multi-Part Enclosure Award , 2005

Gendex Dental Systems (KaVo)

Orthoralix® 8500 Panoramic X-Ray Unit

Project Description:

Gendex Dental Systems and Cesaroni Design product designers developed this diagnostic imaging product. The engineering was handled by our client, while we focused on optimizing a lightweight structure. We worked closely with our client's engineering team to understand assembly and service requirements. 

Multiple medical product design concepts were generated, all of which satisfied the project objectives. We then implemented the chosen concept in 3D CAD. The resulting part files were shared with Gendex's development team for further review.

The adjustable telescopic column is one of the most significant elements of the design. This component makes the unit extremely compact. It also enables the system to accommodate patients of all sizes, including children and wheelchair-bound patients.

Ergonomic diagrams assisted the development team in analyzing the design for the handlebar and chin rest so that the patient is held in a stable and comfortable position. Molded polycarbonate and carbon fiber patient supports are mounted on powder-coated handlebars.

The new product design increases workflow, giving the operator the ability to access mouthpieces and other accessories strategically located behind the handlebar in a rotating storage drawer. Interface elements and electronic controls were developed for ease of use.

The new design of the pressure-formed housing reduces the weight of the product, making it one of the lightest units for the medical industry. Pressure-forming offered low tooling costs and faster speed to market than injection molding. The housing facilitates an effortless assembly in the manufacturing process and installation procedure.

The dental product design earned numerous awards, including a MDEA Silver award, Good Design award and a Multi-Part Enclosure award.

Three quarters front view of the entire Orthoralix 8500 unit
Orthoralix® 8500 Panoramic X-Ray Unit
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Project Description:

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Gendex Dental Systems and Cesaroni Design product designers developed this diagnostic imaging product. The engineering was handled by our client, while we focused on optimizing a lightweight structure. We worked closely with our client's engineering team to understand assembly and service requirements. 

Multiple medical product design concepts were generated, all of which satisfied the project objectives. We then implemented the chosen concept in 3D CAD. The resulting part files were shared with Gendex's development team for further review.

The adjustable telescopic column is one of the most significant elements of the design. This component makes the unit extremely compact. It also enables the system to accommodate patients of all sizes, including children and wheelchair-bound patients.

Ergonomic diagrams assisted the development team in analyzing the design for the handlebar and chin rest so that the patient is held in a stable and comfortable position. Molded polycarbonate and carbon fiber patient supports are mounted on powder-coated handlebars.

The new product design increases workflow, giving the operator the ability to access mouthpieces and other accessories strategically located behind the handlebar in a rotating storage drawer. Interface elements and electronic controls were developed for ease of use.

The new design of the pressure-formed housing reduces the weight of the product, making it one of the lightest units for the medical industry. Pressure-forming offered low tooling costs and faster speed to market than injection molding. The housing facilitates an effortless assembly in the manufacturing process and installation procedure.

The dental product design earned numerous awards, including a MDEA Silver award, Good Design award and a Multi-Part Enclosure award.

Cesaroni Design is a SPE Thermoforming Conference Award winner

Best Pressure Formed Part , 2002

Precor USA

C846 Upright and Stationary Recumbent Cycle

Project Description:

 This is an award winning, recumbent, stationary exercise bike design for the commercial fitness industry. The client's objective was to reduce tooling costs for the new fitness product.

The development team incorporated identical main covers on this new recumbent cycle product design from the client's existing upright bike in order to reduce tooling costs. This design strategy leveraged 90% of the total tooling costs, and established a family look for the client's current fitness line.

We were careful to balance the aesthetics between the two products. The strong diagonal line created by the unique cantilevered seat rail and sculpted side panels semantically represents forward motion, much like a motorcycle shroud. The bold intersection of the front support tube and main body gives the new fitness product a solid look and feel.

Comfort is improved through the ergonomic development of the seat pads that incorporate soft recesses to relieve pressure on the spine and pelvic bone.

This recumbent cycle product design is made for ease of assembly. Design components can be removed through a system of socket head cap screws. Removing only one of the side covers exposes all of the internal mechanisms for service.

This fitness product design received an EID award and was honored at the SPE Thermoforming Conference with Best Pressure Formed Part for the recumbent cycle shroud design.

Side view of the C846 in its recumbent cycle configuration
C846 Upright and Stationary Recumbent Cycle
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Project Description:

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 This is an award winning, recumbent, stationary exercise bike design for the commercial fitness industry. The client's objective was to reduce tooling costs for the new fitness product.

The development team incorporated identical main covers on this new recumbent cycle product design from the client's existing upright bike in order to reduce tooling costs. This design strategy leveraged 90% of the total tooling costs, and established a family look for the client's current fitness line.

We were careful to balance the aesthetics between the two products. The strong diagonal line created by the unique cantilevered seat rail and sculpted side panels semantically represents forward motion, much like a motorcycle shroud. The bold intersection of the front support tube and main body gives the new fitness product a solid look and feel.

Comfort is improved through the ergonomic development of the seat pads that incorporate soft recesses to relieve pressure on the spine and pelvic bone.

This recumbent cycle product design is made for ease of assembly. Design components can be removed through a system of socket head cap screws. Removing only one of the side covers exposes all of the internal mechanisms for service.

This fitness product design received an EID award and was honored at the SPE Thermoforming Conference with Best Pressure Formed Part for the recumbent cycle shroud design.

Cesaroni Design is a SPE Thermoforming Conference Award winner

Consumer Entertainment Housing , 1997

Midway Games

Touchmaster™ Game Center

Project Description:

The Touchmaster™ Game Center features an interactive display for users to choose from any pre-programmed game. The design is compact enough to be ideal for gaming centers but also large enough for the user's enjoyment. 

Three quarters front view of the Touch Master Game Center
Touchmaster™ Game Center
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Project Description:

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The Touchmaster™ Game Center features an interactive display for users to choose from any pre-programmed game. The design is compact enough to be ideal for gaming centers but also large enough for the user's enjoyment. 

Cesaroni Design is a SPE Thermoforming Conference Award winner

Parts Competition Winner , 1996

GE Medical

Advantx X-Ray Table

Project Description:

The Advantx X-Ray Table allows for user comfort while maintaining x-ray accuracy and quality. A more open product environment brings a calming nature for patients, increasing their level of satisfaction with the medical care.

This product was a Parts Competition Winner, sponsored through the SPE Thermoforming Conference.

Three quarters front view of the final production version of the Advantx x-ray table
Advantx X-Ray Table
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Project Description:

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The Advantx X-Ray Table allows for user comfort while maintaining x-ray accuracy and quality. A more open product environment brings a calming nature for patients, increasing their level of satisfaction with the medical care.

This product was a Parts Competition Winner, sponsored through the SPE Thermoforming Conference.

Cesaroni Design is a SPE Thermoforming Conference Award winner

Chairman's Award , 1991

Life Fitness

Life Circuit Strength System

Project Description:

The Life Circuit Strength System is a set of strength machines for users to utilize on workouts for specific muscle groups. The sleek design and easy-to-recognize features make the set easy to use, ensuring user satisfaction. 

Three quarters rear view of the life circuit system
Life Circuit Strength System
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Project Description:

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The Life Circuit Strength System is a set of strength machines for users to utilize on workouts for specific muscle groups. The sleek design and easy-to-recognize features make the set easy to use, ensuring user satisfaction. 

Cesaroni Design is a SPE Thermoforming Conference Award winner

People's Choice Award , 1991

Life Fitness

Life Circuit Strength System

Project Description:

The Life Circuit Strength System is a set of strength machines for users to utilize on workouts for specific muscle groups. The sleek design and easy-to-recognize features make the set easy to use, ensuring user satisfaction. 

Three quarters rear view of the life circuit system
Life Circuit Strength System
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Project Description:

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The Life Circuit Strength System is a set of strength machines for users to utilize on workouts for specific muscle groups. The sleek design and easy-to-recognize features make the set easy to use, ensuring user satisfaction. 

Cesaroni Design is a SPE Thermoforming Conference Award winner

First Place, Heavy-Gauge Category, 1991

Stenograph Corporation

Pro Model Court Reporter

Project Description:

The Pro Model Court Reporter was created specifically for stenographers, particularly in the courtroom setting. Through improved design, this product provides easy typing and accuracy, which are necessities for a courtroom stenographer.

This product was awarded First Place in the Heavy-Gauge Category by the SPE Thermoforming Conference.

Three quarters overhead view of the pro model court reporter molded in textured gray plastic
Pro Model Court Reporter
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Project Description:

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The Pro Model Court Reporter was created specifically for stenographers, particularly in the courtroom setting. Through improved design, this product provides easy typing and accuracy, which are necessities for a courtroom stenographer.

This product was awarded First Place in the Heavy-Gauge Category by the SPE Thermoforming Conference.