Since Worrell began 3D printing injection molds for medical devices, it has slashed lead times by 95% compared to traditional tooling, with costs plummeting 70%. The company, in collaboration with Stratasys Ltd., demonstrates how engineers can accelerate medical device development through the use of 3D printed injection molding, which Worrell refers to as “3D IM.”

“We have recognized a significant under-utilization of the 3D printed injection molding process in medical device development and we’re working with Worrell to help fill this gap,” said Nadav Sella, Senior Manager of Manufacturing Tools at Stratasys.

 

“Worrell is a leading design firm with the expertise and infrastructure necessary to integrate injection molding and 3D printing within the product development cycle. We want to use this collaboration to demonstrate how medical device manufacturers can bring their products to market significantly faster than ever before, continued Sella.”

Medical device manufacturers traditionally face two main obstacles in getting medical devices to market: tooling costs and the FDA regulatory process. Traditional tooling is both costly and time-consuming, as new molds must be created every time a prototype is refined before manufacturing. To reduce potential iteration risks and tooling costs, Worrell uses Stratasys PolyJet-based 3D printers to create injection molding tools and then inject the same materials that will be used in a finished medical device, creating higher-fidelity prototypes.

“We were recently approached by medical device start-up, MedTG, to design and engineer a dual-flow needleless blood collection system that reduced the need for multiple injections, thereby increasing patient comfort and hospital efficiency. Using 3D printed injection molds to prototype the device, we were able to reduce the costs associated with traditional tooling,” said Kai Worrell, CEO at Worrell.

Worrell
www.worrell.com

Stratasys Ltd.
www.stratasys.com