Breas Medical

Breas Medical is a global leader in respiratory care, specializing in CPAP, BiPAP, and high-flow oxygen therapy devices. As a Mechanical Design Engineer with a significant automation background, my core mandate was to initially to eliminate manual bottlenecks in the product Verification and Validation (V&V) process, transitioning the company toward highly repeatable, hardware and software driven testing architectures. My role has also since progressed to include the implementation of AI tools and agentic workflows for our Sydney team and the prototyping of new CPAP Mask components.

Role Context

Respiratory medical device testing is rigorously strict. Devices must be validated against performance benchmarks before regulatory submission to bodies like the TGA or FDA. The legacy process relied heavily on engineers manually running test sequences, monitoring analogue gauges, and transcribing data into spreadsheets. This introduced human error, variability between operators, and significant time-to-market constraints. My focus was to architect end-to-end automated testing platforms from scratch, integrating custom mechanical hardware with robust Python software control layers.

Core Engineering Achievements

The Mechanical Lung Simulator

To simulate real human respiratory mechanics, I engineered a custom motorized mechanical lung. By integrating stepper motors, CO2 sensors, servo-actuated valves, and variable-speed fans controlled by embedded microcontrollers, the system replicates the compressibility and resistance of human lung tissue. I personally machined and fabricated the components using metal lathes and woodworking tools, transitioning the project from rapid 3D-printed prototypes to a production-grade assembly for Hardware-in-the-Loop (HIL) testing.

Closed-Loop Python Control

I built the software control layer entirely in Python. The system utilizes real-time pressure sensor data to maintain precise air flow control based on continuous feedback. Test sequences are defined as structured configuration files, allowing new protocols to be executed unattended overnight.

Automated Brittle Testing System

Beyond respiratory simulation, I programmed an Arduino-driven automated brittle testing system utilizing stepper motors. This standardization allowed for precise and repeatable measurements of part brittleness, guaranteeing mechanical quality assurance across manufacturing batches.

Impact and Results

The shift from manual testing to automated, closed-loop systems delivered immediate business value:

• Reduced V&V cycle time by 7x for standard test protocols.
• Saved approximately $39,000 annually by reducing engineering hours and eliminating manual re-test events.
• Allowed parallel testing of multiple device variants simultaneously.
• Improved data traceability and audit readiness for regulatory submissions by automating data acquisition pipelines.