The Challenge
Medical device prototyping has unique requirements that standard 3D printing services cannot always meet: biocompatible materials, tight tolerances, confidential designs, and documented print processes. When a biomedical startup approached us to prototype their wearable diagnostic housing, we had to meet all four.
Material Selection
We recommended PETG as the primary material. While not classified as a medical implant-grade polymer, PETG is widely used for non-implant medical device housings because it is:
- Biocompatible for skin-contact applications (ISO 10993 tested formulations)
- Easy to sterilise with isopropyl alcohol and UV-C light
- Dimensionally stable enough for repeatable prototype testing
- Available in translucent grades for LED indicator viewing windows
Our Process
Every file received from the client is treated under NDA. Our team reviewed the STEP file for printability, flagged two thin walls (0.6 mm) that were below our recommended minimum, and shared a design-for-manufacturing note before committing to print. The client revised the walls to 1.2 mm and we proceeded.
Parts were printed on an enclosed printer with a calibrated PETG profile, then inspected with digital calipers for critical dimensions. Tolerances were held to ±0.2 mm across all measured features.
Result
The client received three housing variants within 72 hours. All three passed their initial fit tests. One variant was selected for the next prototype iteration and the files were updated directly in our system. Total turnaround from first upload to delivery: 4 days including two design revision cycles.