This specialized case study explores Kymanox’s approach to medical device component design and rapid prototyping through advanced Computer-Aided Design (CAD) modeling and additive manufacturing technologies. Our team of subject matter experts collaborated closely with pharmaceutical device stakeholders to implement measurable improvements across 3D printable component design, Finite Element Analysis (FEA), tolerance optimization, and prototype validation for vial adapter development and manufacturing readiness. This project exemplifies our commitment to providing exceptional Design Support throughout the development process.
CHALLENGE
SOLUTION
RESULTS
- Medical device client required vial adapter component design suitable for both 3D printing and injection molding manufacturing processes.
- Component needed preparation for rapid evaluation and prototyping enabling quick design iterations and accelerated development timelines.
- Comprehensive analyses essential ensuring functionality, proper fit, and manufacturing feasibility prior to production tooling investment and full-scale manufacturing.
- Streamlined development process required minimizing component iterations while maintaining design quality and regulatory compliance for pharmaceutical applications.
- Designed vial adapter component using SolidWorks CAD software ensuring compatibility with both 3D printing and injection molding manufacturing processes.
- Conducted comprehensive FEA and tolerance analyses before physical prototyping to minimize component iterations and development costs.
- Utilized additive manufacturing 3D printing technology for rapid component evaluation enabling quick-turn design feedback and form-fit assessment.
- Created innovative 3D printed injection molds for prototype molding reducing tooling costs and accelerating validation timeline.
- Molded Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS) component using 3D printed tooling and performed comprehensive functionality testing validating design performance and fit.
- Iteratively refined CAD design based on prototype testing results optimizing component performance and manufacturability.
- Successfully developed comprehensive CAD file enabling quick design refinements and modifications supporting agile response to design changes and stakeholder feedback.
- Confirmed component functionality through rigorous FEA modeling and verified precise fit requirements with detailed tolerance analysis reducing physical prototyping cycles.
- Produced fully functional vial adapter component through integrated 3D printing and molding approach validating design readiness for production tooling investment.
- Accelerated development timeline and reduced prototyping costs through innovative use of 3D printed molds and rapid iteration methodology.