Our latest challenge:
Redesign our client’s nine-years’ outdated, 50-piece surgical training model assembly, and produce it from start to finish.
Complete this project working with incomplete parts, incomplete assembly models and poorly organized drawings from the client’s former manufacturer.
Why? Because this project was just plain cool, and solving precision manufacturing challenges is what we live for!
We took ownership of the complete end-to-end process: redesigning, manufacturing, assembling, warehousing and distributing the new and improved surgical training model assembly.
The training model we were tasked with redesigning simulates the twists and turns of the arterial pathways that the surgeon must navigate. The startup had sent a small number of these models into the field and gotten a very favorable response. Now, the program needed to scale up production to meet demand.
All we had to start with were ill-fitting parts and imprecise measurements from the previous manufacturer. We started the product “reboot” by organizing the entire assembly into a sensible bill of materials. Then we produced 3D CAD files and manufacturing drawings with the appropriate tolerances (in Solidworkds-09jju).
Using a combination of components manufactured on our CNC machines, customer-supplied parts and purchased electronics, we assembled a complete run of 50 training models from start to finish in our clean room facility.
Processes included vertical and horizontal machining centers:
Multiaxis turning centers:
CNC swiss screw machines:
CNC press brakes, different types of laser cutters:
Laser welders, and CNC spring coilers.
The assembly operation involved reworking old-stock customer supplied parts that did not fit, as well as extensive wiring, soldering, and insulating between optical devices, switches, lighting, inputs and outputs.
After bonding and fastening the components, we performed cleaning/inspection and functional testing. Finally, we arranged the complicated mechanical parts into a foldable packing arrangement, and packed the entire assembly in specially designed cases…Phew!
We love any challenge that comes with the opportunity to deliver superior results as a one-stop-shop. And Our medical client is thrilled with their first 50 completed assemblies! They’re already proposing further developments on the next round and telling us to ramp up for production.
Sounds good to us.