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Within the medical industry, prototyping is a critical step in the time-, cost-, and labor-intensive process of launching a new product. The medical device prototyping process produces functional samples to exact design and material specifications for use in product testing and evaluation stages and business presentations. These samples enable manufacturers to verify the efficacy and manufacturability of the design and determine whether design changes are necessary before proceeding to large-scale production and market distribution.

Medical Device Prototyping

Producing reliable aerospace part prototypes is a task that relies on accuracy, quality, and strictly adhering to specifications. For the last 11 years while we have specialized in aerospace prototyping, we have gathered relevant expertise that enables us to handle any project touching on aerospace parts, whether simple or complex. Our team of engineers and designers welcomes our customers’ new ideas and thoughts. This approach of listening to our customers ensures that the parts we deliver will provide total customer satisfaction.

Medical Device Prototyping

Leshine Medical Device Prototyping Applications)

  • Handheld devices 
  • Medical carts
  • Medical diagnosis equipment
  • Medical monitor instruments
  • Medical treatment devices
  • Anatomical models
  • Tables and panels
  • Teaching aids
  • Ultrasonic equipment
  • Physiotherapy apparatuses
  • MRI devices
  • X-Ray equipment
  • Clinical analytical instruments
  • Care equipment
  • Surgical instruments
  • Electronic apparatuses

The Medical Prototyping Process

  • Alpha prototypes
    Alpha prototypes are usually non-functioning, reducing the cost of and time required for production. Manufacturers use these 3D printed prototypes to test product dimensions.
  • Beta prototypes
    Beta prototypes are generally created using more refined manufacturing techniques. These prototypes are functional but may not resemble the aesthetic design of the final product. Manufacturers use them to test for functional design or manufacturability flaws and seek out investor funding and consumer feedback.
  • Pilot prototypesPilot prototypes are similar to beta prototypes but more closely resemble the final product. Manufacturers construct these prototypes to exact design and material specifications and use them from soft launches or clinical trials.
    Pilot prototypes are similar to beta prototypes but more closely resemble the final product. Manufacturers construct these prototypes to exact design and material specifications and use them from soft launches or clinical trials.
  • Final product
    The final matured product employs the finalized design that incorporates any of the desired modifications made to the previous prototypes.
  • Medical device prototyping 

    How to Build a Medical Device Prototype

    At Leshine, we rely on several precision machining techniques to build our clients’ medical prototypes, including:

    CNC machining. Our precision CNC machining capabilities, including milling, turning, EDM, wire EDM, and surface grinding, allow us to create complex 3D shapes, geometries, features, and surfaces on metal (including aluminum) and plastic substrates. The machining process produces tight tolerance medical device prototypes and products accurately and repeatedly.

    Clear acrylic machining and polishing. Surface finishing operations, such as clear acrylic machining and polishing, alter the surface of the prototype or product to provide a distinct or desired aesthetic or function. These techniques can change the appearance and add other characteristics to the part, such as greater corrosion resistance or conductivity. For acrylic specifically, the machining and polishing operations facilitate the production of products with high clarity and precision, such as lenses and prisms.

    Aluminum machining. Aluminum is a low-density, high-strength substance. Machining and polishing the material allows manufacturers to produce high quality, close tolerances, products, and prototypes.

    Vacuum casting. Vacuum casting is ideal for creating rigid and flexible parts and prototypes. At 3ERP, we offer hundreds of casting polymers and a variety of color options to select from, as well as turnaround times of 15 days or less for up to 20 parts (depending on part design and volume). Compared to other prototyping methods, such as injection molding, this process provides better surface finishes and is more affordable as the molds are less expensive and more durable.

    Reaction injection molding (RIM). Reaction injection molding produces strong, lightweight parts and prototypes. Compared to other injection molding methods, the process allows for more complex and intricate part geometries at a low cost per part. Additionally, in general, the injection molding process enables repeatable, high volume production (into the millions).

    Rapid Medical Manufacturing On Demand

    Our team can produce an array of medical device prototypes. From small and simple parts and components to large and complex projects, our customers regularly rely on us for a range of applications.

    As an ISO 9001:2015 certified manufacturer, we are proud and honored to provide our customers with comprehensive rapid prototype and manufacturing solutions. Due to our rich and extensive experience in medical prototyping, some of the world’s leading medical and healthcare companies have taken the initiative to partner with us when it comes time to prototype their new products, including:

    • Beckman Coulter
    • GE Healthcare
    • Philips Healthcare
    • Becton Dickinson

    To help clear the rigorous verification and testing procedures of the medical industry, we consistently strive to provide our clients with high-fidelity physical prototypes.

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