Medical Implant Prototype — 48-Hour Turnaround
Emergency production of a custom surgical guide prototype for a complex orthopedic procedure. DFM to delivery in 48 hours.
The Challenge
A surgeon needed a patient-specific surgical guide for a complex orthopedic procedure scheduled in 72 hours. The design was received late Friday afternoon with tight biocompatibility requirements, sharp internal radii, and bone-contact surfaces that could not tolerate burrs or tool marks.
Our Approach
- 01
Immediate DFM review identified radii and wall thickness issues — we returned revised recommendations within 2 hours.
- 02
5-axis machining from Grade 5 titanium billet with dedicated medical tooling and coolant strategy to prevent contamination.
- 03
100% CMM inspection on all critical mating surfaces and guide pin holes.
- 04
Passivation per ASTM A967 and full inspection report packaged for regulatory documentation.
“They delivered a production-quality prototype in two days when we had almost no margin. The inspection report made our internal review straightforward.”
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