The Mini Z

Challenge: Precise Understanding of Real Problems

AS&E initially suggested a traditional pistol grip for their new handheld X-ray scanner, similar to those used in barcode scanners or material analyzers.

However, the Altitude team questioned whether this was the right direction, especially given the component weight of 15.5 lbs. To answer this question, the team conducted an in-depth ergonomic study focused on hand grip, weight, and balance. The team also fabricated various low-fidelity mock-ups based on the ergonomic research and the component dimensions provided by AS&E. These mock-ups were used in initial field tests across different vehicle interiors — the primary scanning environment for the new X-ray scanner.

Through these activities, the Altitude team found that scanning different parts of a vehicle's interior required multiple hand positions, which, combined with the scanner's weight and space constraints, placed significant stress on users’ wrists. Among all options tested, the pistol grip originally suggested by AS&E proved to be one of the least effective. A compact D-shaped handle emerged as the best option during initial field testing.

Limitless Build and Test for the Best Solution that Satisfies Both Ergonomic and Technical Requirements

The team clearly identified ergonomic and environmental requirements through initial field tests and discovered technical requirements from AS&E, including:

• A handle design that is easy to move in narrow spaces and provides balanced weight while scanning

• Robustness to withstand various environments

• A compact overall size to accommodate narrow scanning spaces

• Effective heat dissipation to reduce the risk of malfunction due to overheating components

The team explored design concepts aimed at satisfying these requirements, fabricated prototypes, and conducted field tests. These activities were repeated over multiple iterations to determine the most effective design approach.

The final design decision was made based on insights gained from the limitless build and field testing.

“The Mini Z”: The World’s First Handheld X-ray Scanner, Designed for the Real World

“The Mini Z” redefines portable detection technology, combining cutting-edge engineering with a design process rooted in iteration, collaboration, and real-world usability.

Active communication and collaboration between the Altitude design team and the AS&E engineering team during the component layout study enabled the Mini Z to achieve the most compact size possible, incorporating AS&E’s latest backscatter X-ray technology.

Every design detail of the Mini Z was inspired by the limitless build-and-test process.

Form Born from Field Use: Every curve, contour, and component of the Mini Z was shaped by a relentless build-and-test approach. Field insights directly informed the product’s design evolution—from early mockups to final production.

The narrow, D-shaped handle emerged as the optimal ergonomic solution. Positioned precisely at the center of gravity, it provides intuitive weight balance and effortless maneuverability, especially in confined or awkward spaces. A recessed grip channel within the handle offers ample clearance for gloved hands and diverse grip styles, making the device universally accessible.

Intuitive Interaction: Functionality is embedded into the form. The activation button is integrated into the handle, ensuring easy control from any grip position. Its bold red accent serves as a visual anchor, instantly guiding the user’s eye to a primary point of interaction.

Designed for Durability: Recognizing the operational conditions of field use, the Mini Z incorporates a slightly exposed, over-molded bumper—strategically placed to shield high-wear zones at the front and rear of the device. This protective detail guards against corrosion and impact damage during frequent contact with hard surfaces in tight scan areas.

Thermal Management with Purpose: Aluminum heat sinks are positioned for optimal thermal regulation. Located near the handle, they efficiently dissipate heat while the handle itself doubles as a natural barrier against external shocks, protecting this critical component.

“The Mini Z” is more than a first. It’s a handheld breakthrough, shaped by endless iteration, refined by field data, and designed with the user at the center of every decision.