The story
528 Innovations had a vision to disrupt the clinical and at-home laser therapy markets. They aimed to bring the therapeutic power of a clinical laser treatment to patients’ homes in a way that is safe, more approachable, and more effective than current therapies.
M3 delivered the 5i Series Laser Therapy System, a high-power, modular system that is designed for both clinicians and home users. It supports multiple laser wavelengths modules, hot-swappable battery packs, and an integrated experience across the device and companion app.
M3 helped us translate the problems we had identified and the solutions we had envisioned into the strategy, engineering, industrial design, UX, manufacturing, and brand that ultimately brought the 5i Series to life.
Kevin Johnson
Co-founder of 528i
M3’s engineering team developed a portable Class 3R laser, integrating expertise across optics, mechanical engineering, electrical engineering, firmware, and regulatory compliance. Through functional decomposition, optics design, thermal analysis, and skillful prototyping, the team designed a system that delivered maximum therapeutic output in a safe, compliant package. M3 optimized airflow, material selection, and heat sink design to manage the thermal demands of a high-power handheld device while maintaining a premium look and feel.
M3 developed a system architecture strategy that supported higher power output and multiple laser wavelengths to allow for maximum therapeutic flexibility. This architecture was the starting point for evaluating the product envelope, informing laser safety, and assessing modularity of the laser heads, rechargeable battery packs, and product accessories. M3 explored various concepts around this strategy, resulting in a refined product look, optimized performance specs, and a seamless UI workflow. The 5i Series and its distinctive product identity are now protected by a U.S. design patent.
M3 designed intuitive user interfaces for both the laser therapy device and companion app, conducting user testing with digital mock-ups and physical prototypes. Iterative feedback helped refine navigation, in-app guidance, and detailed treatment tracking to create an optimized experience for both clinical and home environments.
To transition the design into production, M3 partnered with the contract manufacturer to establish a robust, repeatable build process. The team supported process development, fixture design, manufacturing documentation, and production ramp-up to ensure consistent product quality and throughput. Hands-on collaboration helped resolve issues quickly and align manufacturing outputs with design intent. This effort ensured the device met performance, reliability, and scalability requirements.
Architecture
Early strategic work identified key success criteria and system risks that needed to be addressed during the architecture definition. By tackling these needs early on, the architecture could be trusted to carry the demands of the system moving forward and eliminate the risk of disruptive changes later in development. This architecture was the foundation of the industrial design concepts to follow.
Touchpoints That Matter
Through steadfast focus on critical user touchpoints such as the button pad, LCD screen, and material finishes in support of our industrial design and UI/UX research, M3’s designers and engineers executed the envisioned product look and feel and delivered a premium experience.
Optical & Thermal Design
Laser-based medical devices must balance rigorous performance requirements with patient safety considerations. For the 5i Series, this included engineering the optical system to achieve the desired power and delivery characteristics while maintaining its Class 3R laser safety classification. M3 integrated wavelength-specific laser diodes and engineered diffusers to achieve these objectives, while thermal analysis and testing helped ensure reliable performance within the compact handheld design.
Production Fixtures
M3 developed custom assembly and test fixtures to support critical manufacturing operations. Production fixtures ensured precise alignment of optical components and provided stability when working with sensitive assemblies. Additional test fixtures were created to ensure safe optical output and verify functionality across key subsystems during production. These tools improved consistency, reduced variability, and enabled efficient quality control on the manufacturing line.
UI/UX
User Research
M3 leveraged prototype testing and user feedback to refine navigation, functionality, and interactions across the laser device and companion app. Insights from clinical and home environments informed a cohesive experience tailored to real-world user needs.
UI Ecosystem
M3 implemented a directional keypad for intuitive navigation, addressing concerns around prolonged use, safety, and hard-to-reach treatment areas. Iterative prototyping and user testing refined the experience, while workshops and user feedback informed app features such as guided programs, device controls, and session history. Consistent visuals and color cues created a seamless experience across the device and app, enhancing readability and usability.
Interface Elements
M3’s UI/UX team leveraged user feedback to develop in-app instructions and guidance that improve clarity during laser therapy. Consistent communication, visuals, and functionality across the device, app, and packaging create a seamless user experience that enhances usability, builds confidence, and enables intuitive operation.
M3’s integrated approach enabled 528 Innovations to bring a complex, high‑power therapy device from an idea to production. By aligning performance, usability, and manufacturability early, the team delivered a reliable, scalable solution for both clinical and home use. The result is a refined platform that expands access to effective laser therapy.
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