““When Project Management asked R&D to update the three machines in the National Optronics product line, we knew it was going to be a heavy lift. We needed new housings, updated displays, and new core electronics. Our internal mechanical engineering resources were already stretched thin.
We didn’t need three different vendors—one specialty shop to make pretty pictures, another to handle detailed injection molding design, and a third to do our sheet metal. We needed one design partner who could do it all. SPARK was my first call.””
Satisloh North America
Ophthalmic Equipment Manufacturer | Product Family Redesign
Satisloh North America is the U.S. division of the global Satisloh Group, a leading manufacturer of equipment and consumables for the ophthalmic lens market. Although part of a 1,000-person multinational company, Satisloh's North American R&D team is small, with only one person focused on mechanical engineering and design.
When the team set out to modernize its National Optronics brand of tabletop lens finishing machines, they needed a partner who could move quickly, work within tight technical constraints, and bring a fresh but cohesive design language to the full product line. They chose SPARK, a long-time collaborator with deep familiarity with the product and its users.
The Challenge
Satisloh was updating three distinct machines used in optical labs—a tracer, a blocker, and an edger. Each had to transition from tactile keypads and standalone displays to sleek touchscreen interfaces. The client wanted the products to feel more modern and visually unified, especially since they are often sold and installed together.
There were also key constraints to navigate. The internal mechanical systems could not be significantly altered, so SPARK had to work within the existing footprints and mounting points. In addition, the edger needed to support either of the other machines on top to conserve space in compact lab environments. And while the new designs needed to signal innovation, they also had to maintain some continuity with the National Optronics brand.
The Solution
SPARK led the industrial design effort and supported Satisloh with design and detailing throughout the engineering process, taking the project from early sketches through to production-ready deliverables.
The process began with concept exploration. Working closely with the Satisloh team, SPARK:
Created hand-drawn sketches to explore ideas around form, proportions, and interaction zones
Built full-size foamcore models to test ergonomics and the user experience
Developed rendered CAD models showing all three machines side-by-side, helping the client evaluate different options for a unified product family
Once Satisloh selected a direction, SPARK moved into detailed engineering for the new machine enclosures. The team:
Designed part splits and surfaces optimized for injection molding and reaction injection molding (RIM)
Identified challenging transitions and surfaces to avoid cosmetic issues in production
Provided cost estimates for tooling and parts to guide decisions around aesthetics, complexity, and long-term production costs
Delivered final CAD models and production-ready drawings aligned with Satisloh’s internal engineering standards
Offered ongoing support during manufacturing, ensuring the designs could be executed accurately and efficiently
The Impact
Satisloh launched a redesigned product family with a unified and modern appearance, all while maintaining cost efficiency and internal performance.
With SPARK’s help, the company was able to:
Introduce a cohesive new look across three core products
Preserve the internal structures and meet space-saving requirements
Keep cost of goods in line with the previous generation of machines
Streamline collaboration and decision-making despite limited internal engineering bandwidth
Strengthen their brand’s visual presence without compromising on manufacturability or usability
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“Every design project involves trade-offs between cost, quality, and speed. SPARK doesn’t magically eliminate those trade-offs, but they understand them and helped me think through the implications of each design decision. The final products speak for themselves—slick, modern, integrated. We couldn’t have gotten this project done and delivered with quality without SPARK’s partnership.””
Why it matters
Creating one well-designed product is challenging. Designing a complete product family that looks consistent, works within existing mechanical constraints, and aligns with brand expectations takes careful collaboration and technical skill.
SPARK helped Satisloh achieve that goal. This project shows what can happen when a small internal team is backed by a hands-on partner who understands both the big picture and the smallest manufacturing detail. The result is a clean, connected product line that balances cost, usability, and modern design.