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Medical Device Prototyping: All You Want to Know

rapid-prototyping-medical-device
Austin Peng
Published 18 Jul 2024
Table of Content

The medical sector has revolutionized the world with its progress in modern technology. A lot of life-saving medical devices are invented every day in the world. Before going into mass-production, medical device prototyping is developed to test its various features and design technicalities. DEK offers state-of-the-art medical device prototyping to its local and international customers.

A complete guide is provided below to answer all of your possible queries. You can also reach out to our technical support team in case of any further technical or design-related queries.

What is Medical Device Prototyping?

What-is-medical-device-prototyping

Medical device prototyping is the process of creating functional samples according to the design and specification of the product for testing, evaluation, and business presentation purposes. These prototypes help manufacturers to check the efficiency and viability of the design and determine whether there is anything that needs to be changed before the product move into large-volume production and market distribution.

The 3D design might look ideal and revolutionary but it actually brings the problems to the front when held in hand. So prototyping is crucial in the medical industry and a critical step to save the time and the cost of the labour extensive process of introducing the new product.

What Are The Common Medical Devices That Need Rapid Prototyping?

What-are-the-common-medical-devices-that-need-rapid-prototyping

There are so many different medical devices that are used on daily basis in the health sector that require rapid prototyping to present a three-dimensional realistic representation of devices. Let’s have a look at some of the devices that need rapid prototyping in the below-mentioned section.

Medical devices and Instruments

Scalpels, retractors, surgical fasteners, display systems, and many other devices are developed with the help of rapid prototyping. Other areas that are looking at rapid prototyping technology for the development of prototypes are teeth replacement and some drug doses. Tablets that require sustained drug release also use rapid prototyping technology and this technology has also minimized the adverse drug reactions.

Prostheses and Implants

Rapid prototyping has made its impactful role in implantations and prostheses. With this technology, you can get specific protheses specially designed for particular patients at an affordable cost. A great example of rapid prototyping for medical purposes is using CT scans in hip replacement surgery. Data from the CT scan is combined with some other engineering data and then turned into a plastic model through rapid prototyping to be used as an implant for the patient.

Planning for Surgical Procedures

Complex body organs models are developed through rapid prototyping that is used by surgeons to get the real impressions of the organ before the surgeries. Rapid prototyping helps to manufacture biological implants and also in tissue engineering. These applications use selective laser sintering (SLS) of ceramics.

Why Do You Need Medical Device Prototypes Before Production?

Why-do-you-need-medical-device-prototypes-before-production

Medical devices are an integral part of the medical industry and their application and performance are crucial for patients. Therefore it is necessary to have a prototype before the production to test, evaluate and perform the required assessment of the product before sending it to final production. Let’s discuss some of the important aspects of medical devices prototyping.

Room for modification: The prototype before production provides clarity and enhancements required. The possibility of identifying the modification and improvements is higher in prototypes as compared to analyzing the design.

Save Time and Cost: Prototypes save the cost and time involved in modifying the overall production over a single prototype. If the issue is identified in the prototype at the primary level the level of error can be minimized and saves the wastage of time and resources.

Customization:CAD file offers a wide range of flexibility and the prototype can be changed into various designs and shapes. This helps the idea to change into multiple forms and check its economical and manufacturable feasibility,

Communication: A physical model in your hand can communicate way better than a design in your head. It communicates design and manufacturing challenges.

Compliance: Prototyping can help you evaluate the process are in line with the regulatory guidelines of the FDA. If not, you can change the process or the part of the prototype that does not comply.

Patent Overlap: When you working on a product for the competitive market, you want your product to be unique. In the process of prototyping, you can check if your product features are overlapping with the existing product and change accordingly.

What Manufacturing Technologies Are Used to Produce Medical Device Prototypes?

CNC Machining

CNC-Machining1

CNC machining is a numerically controlled computerized machine that removes material from various objects by different forms of cutting such as turning, milling, grinding, and drilling. The computer feeds the information to the machine to navigate into different positions and speeds along with specific paths to achieve the required results. CNC machines are used for producing many industrial prototypes and it is considered as the finest process to get the most accurate medical prototypes.

CNC machines are widely used to produce medical prototypes and It has the capability to produce prototypes from distinctive materials such as different grades of metals and plastics. You can achieve an impeccable level of accuracy and intricacies with a CNC machine.

Doctors rely upon the precision and quality of medical devices and equipment and it is necessary to produce prototypes that are accurate and up to the mark to help the doctor get positive outcomes for the patients. CNC machined is the best possible process to manufacture high precision equipment with complex geometries needed for the medical devices and instruments. CNC machined medical prototypes come with critical features and tight tolerance.

3D Printing

3D-Printing1

3D printing involves creating a three-dimensional structure from the digital file by extruding the molten plastic from the tiny nozzle that is controlled by the computer. It prints the one layer and waits for the object to dry then adds another layer on the top. The material used in medical prototyping is silicone rubber, urethane, epoxy, Acrylonitrile Butadiene Styrene (ABS), PC/ABS, Nylon, Acrylonitrile styrene acrylate (ASA), Polycarbonate (PC).

3D printing helps to create so many medical devices with cost-effectiveness. Not only this, but it also provides flexibility, fast prototyping, customized design, and wider choices of material as compared to other production processes. This technique is used for creating prototypes for different parts of equipment used in the medical industry such as prosthetics and implants, anatomical models, tissue and organ fabrication, personalized medical products, and equipment.

3D printing is a phenomenal process to test, evaluate and examine medical devices like stents, catheters, syringes, cardiovascular devices, drug delivery systems, etc.

Vacuum Casting

Vacuum-Casting1

It is a process that uses a vacuum to draw liquid casting material (plastic, rubber, etc) into a mold to cast a final part. Medical prototypes created from vacuum casting are of very high quality and can be used for multiple testing and evaluations. Nowadays, medical products normally use the form of a shell created by panels, keyboards, and other interactive elements. This material uses soft elastomers and other rubber-like materials for coating purposes.

The molding of different materials can be achieved by vacuum casting and injection molding but injection molding is quite expensive and time taking. Parts produced for the medical sector must contain a wide range of chemical and mechanical properties. They should be easily cleaned, have to be sterilized, chemical and heat resistant, biocompatible, transparent, etc. The vacuum-casted resin can meet all these requirements helps new medical designs to get approved by the FDA.

Does DEK Offer Rapid Prototyping Services for Medical Devices?

Does-DEK-offer-rapid-prototyping-services-for-medical-devices

A big YES, we at DEK is a rapid prototyping services provider from China with more than 10 years of experience in rapid prototyping. We have worked with different industries around the world especially with the medical sector and delivered them accurate prototypes that meet their unique requirements. We pride ourselves on providing quick response time, stringent quality control, and firm material verification for your medical prototypes to ensure you get the best possible prototypes.

We offer a wide range of techniques to produce multiple medical prototypes such as 3D printinginjection moldingCNC machining, vacuum casting, and so many other processes. With the help of these modern techniques, we can offer the customization and flexibility you need for building prototypes with intricate and accurate structures.

Our top-notch engineering team has produced health monitors, drug delivery devices, fitness trackers, enclosures, and cases for different medical devices, prosthetics, and other medical equipment for our widespread clients.

Does DEK Offer Surface Finishing Services?

Does-DEK-offer-surface-finishing-services

Yes, DEK offers high-quality surface finishing services for the components and parts no matter what production method they have gone through. Our extremely skilled experts can complete your finishing project with exceptional quality and within the time frame.

Surface finishing not only makes your prototype presentable and aesthetically pleasing but also ensures they perform as intended. Surface finishing adds the protective layer outside the prototype and makes it corrosion and rust protective.

We make sure to enhance the durability and cosmetic appearance of your medical prototypes and models with polishing, electroplating, brushing, laser engraving, anodizing, painting, chromed and metalizing, sand and bead blasting, heat treatment, powder coating, and many other services.

If you are seeking exceptional surface finishing service for your medical prototypes and other components then get in touch with us and our customer support agent will answer your all queries and will get your project going.

Does DEK Offer Parts Assembly Services for Medical Devices?

Yes, We at DEK are supported by experienced and skilled personnel with modern technological machinery to provide the highest quality medical equipment assembly solution from the concept to the final product. Different electronics and equipment play a crucial role in many diagnostic and treatment applications in the medical sector.

Due to this critical function and sensitive nature these devices must be assembled and constructed very carefully to ensure the safety of both medical personnel and patient. This makes us integrate high functional and quality printed circuits in assemblies to ensure accuracy, speed, and durability.

We are expanding our capacity and are always looking to set up cost-effective and efficient assembly lines for our customers to ensure their every product specification is met and their product comes out as high performing.

We help our clients to get the best competitive solution by optimizing their assembly process with our expertise and ideas. As an FDA-compliant manufacturer, we deliver service that meets the most demanding standards. We aim to improve the reliability and quality of your components and at the same time minimize cost and time.

Does DEK Offer Mass Production Medical Devices?

Yes, we work with different medical industries and transform their preliminary drawings and product ideas into a wide variety of end products from prototyping to mass production. We specialize in the design and production of complex medical instruments, tools, measuring instruments, and medical devices. Our mass production facility has an integrated production system for handling material from start to final processing.

With the production system that conforms to the law required by the FDA for the manufacturing of medical devices, we say yes to every mass production order. With DEK’s detailed inspection of specifications according to the usage of the medical devices, we develop and supply the best possible optimal and high-quality products that strictly follow the client’s specifications and meet their expectations.

How to Order?

Do you have questions about your medical product design? Are you looking for a partner to collaborate with for your medical devices prototypes? Even if you are halfway with your idea and design and still working on it, you are at the right place for your prototype consulting and production. Let us know what are you looking for and we will get you going.

We have created an order management system that made it easy for our customers to order and keep the track of their orders and get updated whenever they want to. You can just fill out our forms and our support agent will get back to you with a quotation. You can also email us or call us on the mentioned number on our website for any queries and to place your order.

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Austin Peng
Co-founder of DEK
AUTHOR
Hello! I'm Austin Peng. I manage a factory that specializes in CNC machining, injection molding, and sheet metal fabrication for small quantity production and rapid prototyping solutions. When I'm not immersed in work, I love diving into football matches, exploring new travel destinations, enjoying music, and staying updated on the latest tech trends. Feel free to chat with me about anything, whether it's work or life!

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