Request Copyright Permission

3D Printing and Beyond: Effective Use of Rapid Prototyping to Accelerate Medical Device Development

Maltz DS, Axford G, White GM, Glusker M.

RDD Europe 2015. Volume 1, 2015: 155-164.

Abstract:

Medical device engineers have always depended on prototyping as a key part of the development process. After determining the key requirements for a device, a series of iterative cycles (Design - Build - Test - Repeat) bring a device closer to realization through a series of prototypes with increasing fidelity [1]. The speed and cost of these iterative cycles depend on many factors, but two that stand out as critically important are the throughput and the resolution of the prototyping process. To be truly effective, throughput for early design cycles should ideally be high enough to get a relatively crude prototype or small set of prototypes into the hands of the engineer overnight. Later in the development cycle, when the design is changing less rapidly, turnaround time becomes less crucial and the ability to resolve details accurately increases in importance. Over the past decades, rapid prototyping (RP) has increased in sophistication and power. At the same time, costs have come down and ease of use has improved, putting more capability directly in the hands of engineers. In this publication, we provide an overview of several RP processes: subtractive RP methods such as laser cutting and benchtop milling, additive RP processes (i.e., 3D printing), and quick-turn injection molding. We also share a real-world perspective on how, when, and why one development team has employed certain RP technologies to speed the development of medical devices, including, but not limited to inhalation drug delivery systems.