Biomedical device front panel: prototypes for tests and productions in ABS-like material

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Customer objective: to validate the development of a new product in the engineering phase with aesthetic but also functional prototypes. Subsequently define a production technology for very limited runs since it is a highly customized device.

Coesum solution: For the first phase we evaluated to produce the pieces in sintering of nylon powder or stereolithography. With the validation of the engineering we went to production through replicas from the silicone mold to ensure a yield suitable also for the marketing of the device.

Result: for the first prototype made in stereolithography it took a few days, for the next step three weeks from the approval of the final mathematics.

The endofaster device developed by NISO Biomed enriches and improves the examination of gastroscopy through the real-time analysis of gastric juices. The indications in a few seconds provide an alert for risk factors for stomach cancer and the diagnosis of Helicobacter Pylori, improving diagnostic accuracy, reducing invasiveness (shorter examination without biopsies) and reducing hospital costs.

At first Niso Biomed’s need was to produce at most two prototypes of the front panel to validate the engineering under development. They chose stereolithography to have a first ABS-like model.

The next step was to identify the best production process. Given the high customization and very limited production runs of the product, the most suitable solution was the realization of a pre-series by vacuum casting from a silicone mold. We used the PX2017 HT material, an ABS countertype. This step allowed the customer to assemble the complete machine with a limited investment and in 4 weeks to have the first production pieces to start the marketing.

This technology is linked to rapid prototyping technologies since the starting point is always the construction of a first prototype in stereolithography which is used as a model to build the silicone mold. The casting process takes place under vacuum and allows the production of about 25 pieces. In all cases in which the print runs do not exceed the dozens of pieces per year, it is a suitable technology for producing pieces in ABS-like with excellent aesthetic and functional performances so as to be similar to particular products with plastic molding.

To meet the requirements of the safety regulations, the front has been made with additives that confer a degree of flame resistance V0 according to UL94.

Thanks to Niso Biomed for choosing us as a partner in the production of their device

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