Modern medical device manufacturing utilizes a variety of methods for prototype development and high-quality biomedical products. As device needs become more complex, speed to market becomes essential and parts develop at a higher quality, additive manufacturing has quickly established itself as a standard process for prototype production and medical device manufacturing.
Additive manufacturing (AM) is synonymous with 3D printing, used in a variety of developments and applications. In the medical field, AM utilizes biocompatible materials such as metal alloys to create devices, implants and even human tissue. Medical device production is optimized with additive manufacturing techniques to create high-quality, complex parts quickly and cost-effectively.
Using CAD software, AM can build out layers and complex designs to assist engineers in creating prototypes or parts that would otherwise take excessive time and energy to make. By using additive manufacturing techniques for medical devices, engineers are able to increase the quality and optimize the performance of our partners’ projects.
Material Extrusion
Material extrusion is one of the more common additive manufacturing techniques for medical devices. Used for rapid prototyping or even for hobby 3D printing, material extrusion is fast and relatively inexpensive. By reading the CAD file, the 3D printer feeds material filament through a nozzle capable of moving on an X, Y and Z axis.
Once the first layer is created, the printer repeats the layering process continuously, fusing the layers together as it goes. Material extrusion enables engineers to get a device or part in hand sooner, and can use the part to apply testing or further ideation more effectively. While this is an excellent technique for the early stages of development, material extrusion typically is less reliable and durable as other additive manufacturing techniques.
Binder Jetting
Binder jetting, also referred to as ink jetting, is another cost-effective method for additive manufacturing. Using affordable and durable materials such as sand, ceramics and metals, binder jetting creates a powder and spreads it over a bed to form a layer from the CAD file.
During the process, the machine will apply a liquid binding agent to the powder. Once the part or device is completed, necessary post-processing steps such as sintering for metal materials are applied. These steps ensure the quality and durability of the final product. Because the material is strong and simultaneously lightweight, binder jetting products can be used for more permanent needs in some cases.
Directed Energy Deposition
Finally, one of the more accurate. high-quality additive manufacturing techniques for medical devices is Directed Energy Deposition (DED). Just like its counterparts, DED deposits material on three axes to create complex parts and devices. Through the Directed Energy Deposition process, materials are melted through the nozzle and solidify onto their printing surfaces.
DED utilizes either wire or powder materials, depending on project needs. These machines are highly accurate, and they enable the creation of larger parts and devices. By implementing different materials, Directed Energy Deposition can create large, complex parts with a high degree of accuracy and durability. The materials engineers use for these parts are often biocompatible, meaning they can be used in final projects such as implements or patient technology.
Modern Manufacturing at the Highest Standards
Additive manufacturing has become an industry standard for medical device development. Its versatility, reliability and speed enable engineers and developers to get prototypes and products in hand faster. Through refined layering processes, 3D printing has changed the way device manufacturing is done, and it has improved many processes and standards that are used every day.
At Nextern, we use the latest technology and additive manufacturing techniques to ensure the parts and devices we create are of the highest quality. Our ability to create prototypes from a variety of materials and manufacture complex parts in-house has raised our standards for better products. Contact us to learn how we can power your device using highly accurate and reliable technology.
Artificial Intelligence
Artificial intelligence (AI) in medical device technology has improved the automation and efficiency of device manufacturing, manual processes and more throughout the medical industry. AI has improved medical device technology thanks to its ability to take on menial, redundant tasks. For example, Robotic Process Automation (RPA) can be integrated into pharmaceutical applications. The automation streamlines tasks that are time-consuming and boring, such as prescription validation. By integrating artificial intelligence into medical device technology, medical practitioners are able to focus on more complex tasks and processes. AI enables manufacturers, developers and medical professionals to more precisely accomplish their duties and can rest assured that their work is accurate and efficient without compromising quality.3D Printing
While 3D printing has been incorporated into medical device manufacturing and other processes since the 1990s, it has propelled the industry forward significantly in the last decade. 3D printing is a pillar of modern medicine and medical device technology. Engineers, manufacturers and practitioners can use 3D printing to create a number of instruments, including prosthetics and implants. Modern medicine has launched into efficiency and affordability thanks to 3D printing technology. Device developers integrate 3D printing to create rapid prototypes and to more efficiently mass-produce final products. 3D printing allows engineers and developers to get a device in hand quickly and with a durable, high-quality material. As medical device technology continues to evolve, 3D printing will likely remain at the center of future developments for these reasons.Internet of Medical Things
Modern technology is synonymous with connectivity and the internet. The medical industry has applied these modern standards of connectivity to coin a phrase known as the Internet of Medical Things (IoMT). Modern medical devices require reliable and secure internet and bluetooth connectivity for effective patient care. Wearable devices, including medicine-delivering implements and remote patient monitoring devices are made viable thanks to reliable connectivity. IoMT technology has allowed these devices to exist on a more reliable and secure scale. In addition to wearable technology and devices, modern medicine has integrated IoMT into daily patient care. The most prominent example of this can be seen in telehealth appointments, which exploded in popularity and necessity after the COVID-19 pandemic. As patients, providers and developers seek care and medical device technology through a more remote connectivity, the Internet of Medical Things has become essential for bringing patient care to those around the globe. Not only does IoMT allow patient care and modern medicine to operate on a larger and more remote scale, but it also encapsulates necessary security and privacy. Medical device technology necessitates that patient information and other data is encrypted and secured across devices. Even a decade ago these concerns were much larger than they are today with the advent of a more robust network and seamless integration of wireless internet connectivity. The future of healthcare will rely on IoMT as developers, providers and patients experience a world shifting to virtual connectivity.Augmented Reality and Virtual Reality
Similar to other technologies, augmented reality and virtual reality have existed for years. Over time, however, the capabilities of these technologies have developed to be incorporated into medical device technology and use. Augmented reality in the medical industry can be used for patients, doctors and even medical device manufacturers. Because AR is used to show overlays or in-depth renderings of an environment, patients can better describe issues, pain or other needs more accurately. Doctors can more accurately treat their patients or prepare for a surgery. And device manufacturers can integrate AR to inform their prototypes, their production or even simply their proof of concept phases. AR has become increasingly refined and perfected to accurately depict the world and environments and in doing so, lends a hand to medical device technology as engineers and others work to develop and improve patient care. Virtual reality, on the other hand, has helped put care into more practical uses. Surgeons, for example, can prepare for an operation by virtually performing a surgery or familiarizing themselves with different aspects of an operation. This reduces risk while operating on patients and can improve patient outcomes and care. The developments and optimization of AR and VR have begun to be incorporated into the medical field to allow practitioners and medical device developers to better understand their patients’ needs and provide solutions. This is a large step forward in providing expert, refined care and creating medical devices that have an impact.Find the Future of Medical Device Technology
As new technologies become available, many engineers and developers look for ways to incorporate them into manufacturing medical devices. Evolving technology leads to evolving devices and finally, to better patient care. Patients, doctors and end-users directly benefit from improving medical device technology such as AI, 3D printing and VR. The future of medical device technology is already here, and Nextern is working to bring it to market. Our partners’ medical device projects encompass wide ranges of purposes, goals and technology. From refining an implant to creating a completely new body-worn device, our developers and engineers incorporate leading technology and capabilities into every stage of medical device development. Find the future of medical device technology with Nextern and see how we can improve patient care together. Contact us and get started on your next medical device project.Follow us on linkedin!
Computer-Aided Design
Computer-Aided Design (CAD) is one of the most common methods for collaborative engineering today. The software enables remote and collaborative design across the globe. CAD software has become an essential component of the medical device development process, where designers and developers can access the technology from anywhere in the world. This is especially relevant in a more remote-based work environment, but even prior to the effects of the COVID-19 pandemic, CAD software was used prominently across industries, including the medical device development industry. The benefits of using CAD software for collaborative engineering are extensive. Users are able to begin and edit projects more quickly, efficiently and clearly than traditional methods. In addition, designers can share files remotely, which enables collaboration across platforms, computers and physical locations. Medical device development benefits from CAD software thanks to its robust capabilities, including the ability to create 3D renderings, refined measurements and specs that are accurate to the final product. CAD outputs as electronic files and code that is able to be sent to engineers and manufacturers for future development. Engineers can take CAD files for computer-aided engineering, whereas later in the collaborative engineering process, manufacturers rely on CAD files for laser cutting and 3D printing.Computer-Aided Engineering
Computer-Aided Engineering (CAE) streamlines the device development process for engineers, enabling them to create virtual renderings of a product or a part of a product. CAE is a vital part of the collaborative engineering process, acting similarly to a virtual prototype of sorts. Engineers use CAE to simulate medical device performance, including movement and design. Through this method of collaborative engineering, developers and engineers can optimize various iterations of a design and improve what will become the final product. Computer-Aided Engineering also assists in resolving engineering conflicts remotely, allowing users to collaborate on a design simultaneously and simulate how a product will look and act during final production. Engineers are able to leverage CAE to test and resolve processing steps during device iteration, including:- Stress and dynamics
- Kinematics
- Mechanical event simulation
- Optimization of final product, similar to beta testing
- Simulation of final manufacturing process including casting, laser cutting and printing
Computer-Aided Manufacturing
One of the most robust and groundbreaking methods for collaborative engineering comes in the form of Computer-Aided Manufacturing (CAM). Through the use of computer systems and programs, manufacturers across different platforms can interact with a unified interface to output a physical product, oftentimes given from a CAD or CAE file. Machinists use CAM technology to create a device through numerical control and a coding language known as G-Code. The process of using Computer-Aided Manufacturing is repeatable and exact, making it instrumental in the collaborative engineering process. The outputs of a CAM process vary based on the project and specifications of the device. Typically, a CNC or metal cutout is done through CAM code. As technology and collaborative engineering methods evolve, different outputs have become available, including 3D printing and more. The entire collaborative engineering process relies on Computer-Aided Design and Computer-Aided Engineering to finally output a final product or prototype through Computer-Aided Manufacturing. At this point in the device development process, the project has gone through many iterations and optimization processes, resulting in a near-final product ready for beta testing or final manufacturing on a large scale.Collaboration and Innovation: Enabled
As the methods for collaborative engineering evolve, so too does the medical device development process. Technology such as CAD, CAE and CAM enable intercontinental collaboration to streamline development and get high-quality products to market quickly and efficiently. Collaborative engineering enables designers, engineers and manufacturers to navigate supply chain demands by diversifying and outsourcing different specialities and capabilities to others who are set up to handle different aspects of the development process. With global collaboration and resources at an organization’s fingertips, medical device manufacturing is made more efficient and with a higher quality finish. At Nextern, we have refined the collaborative engineering process through a global diversification of resources and capabilities. With device development facilities in the United States, Costa Rica, China and Vietnam, we are set up to manage the medical device development process at all stages to ensure your project gets to market quickly and efficiently, at the highest quality possible. If you want to learn more about how our collaborative engineering team works to achieve your goals, contact us. We are ready to help you design, develop and manufacture your device concept into a leading product for patient, doctor and provider use.Follow us on linkedin!
3D Printing
While 3D printing has been utilized in the medical device industry since the 1990s, it has widely become the preferred method for creating medical device prototypes and components. In 2022, medical device production has been streamlined thanks to both SLA and FDM 3D printing. FDM printing allows for large quantity production, while SLA printing can create smaller prototypes with refined detail. 3D printing in the medical device field helps engineers get a product in hand more quickly by bypassing the injection molding process. Injection molding has been a common method for creating medical device prototypes until recently. By utilizing 3D printing, engineers can test the device faster to make improvements easier and more efficiently.Wearable Devices
Modern patient care is starting to integrate wearable devices on a massive scale. These devices make treating patients and monitoring health easier for both patients and providers. Wearable medical devices can deliver insulin and other medicines while simultaneously tracking patient health metrics such as heart rate, blood pressure and oxygen levels. With an increase in wearable medical devices, Nextern is focused on improving patient outcomes and optimizing the user experience. Devices that are worn should be comfortable, sleek and effective. In 2022, our designers have emphasized these qualities to create wearable devices that promote better care and comfort. Accurate readings, precise monitoring and fast delivery are key for safety and health. As we prepare for an increase in similar medical device technology, we keep these aspects top-of-mind to ensure all devices are easy to use, accurate and effective.Implants
In 2022, implants have also made a difference in treating patients. While implants have been prominent in the medical field for many years, improvements to the technology show promise for the future of patient care. Medical device implants are becoming slimmer and less intrusive for patients. Some implants can even be installed through minimally invasive outpatient surgeries to promote faster recovery times and a better patient experience. The technology that equips the implants is also improving. Some implants are able to track patient health, similar to pacemakers and heart rate monitors. Other advanced medical device technology can target and treat specific conditions such as paralysis. These neurological implants can stimulate the brain and encourage activity to patients with various types of paralysis. Nextern and Nextern NPX utilize biocompatible metal alloys and refined technology to create new devices and implants that improve patient care.AI Technology
Artificial intelligence (AI) may seem futuristic, but it has found its way into modern medical devices. By incorporating AI into device development or even the device itself, engineers can accurately track and extrapolate information for better care and long-term development. AI’s capability to monitor data and find patterns can actively inform device engineers and doctors. In addition, AI in medical devices can detect and warn of early signs of illnesses such as sepsis. With this new medical device technology in place, engineers can develop medical devices that are compatible with AI and can track patterns and symptoms for improved patient care down the line.Nextern Continues to Develop and Learn
As world-class medical device manufacturers, we understand the importance of keeping up with the latest developments and implementing new technologies into our work. With a global network of designers, engineers and manufacturers, Nextern is ready to incorporate tomorrow’s technology into your medical device. From 3D printing prototypes to incorporating AI-compatible technology, we have experience designing and developing user-friendly medical devices across many medical fields. We are dedicated to bringing the latest medical device developments to life and optimizing products for improved patient outcomes. Contact Nextern and join a collaborative team dedicated to bringing your medical device project to market.Follow us on linkedin!
Decades of Experience
NPX Medical has established themselves as industry leaders with world-class facilities. Their robust capabilities will augment Nextern’s prototyping and development process. Paul Hindrichs, President of NPX Medical, said this about the collaboration: “NPX is proud to join the world-class manufacturing team at Nextern where we will combine forces to help power a more robust suite of medical device enablement capabilities to help our partners in improving patient outcomes and bettering day-to-day lives worldwide.” Nextern will provide the infrastructure and resources necessary for NPX Medical and their clients to grow, and offer them a path to market with manufacturing capabilities both locally and internationally. Rich Farrell, CEO of Nextern, Shared his thoughts: “Nextern’s mission is built around collaborative medical devices, and we are looking forward to bringing that mission to the next level with NPX Medical. With our combined resources and experience, we will bring innovative systems, equipment and greater speed to market to both NPX’s and our partners.”Medical Device Enabled
Nextern enables partner medical device innovators to plan, design, build and manufacture medical devices that are changing the world. Our team of experienced engineers, technicians, and designers collaborate to bring ideas, prototypes or existing products to market faster. Our team advances innovative design and development programs backed by our commitment to agile and premium manufacturing. We provide visibility on our process to our partners every step of the way, from design documentation to active production runs. The teams at Nextern and NPX remain committed to delivering best-in-class medical devices and instruments to move the industry forward and improve patient outcomes.Follow us on linkedin!
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