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A Global Search for Precision

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Nordstar Medical, based in Denmark, initially faced a significant challenge: finding a supplier capable of producing extremely small, intricately detailed components for their innovative catheter. Their internal search yielded no suitable solutions. They explored many options, but the results fell short of their exacting requirements. This led them on a global search, ultimately bringing them to NanoVoxel. Their initial contact involved a test run, a crucial step in evaluating NanoVoxel’s capabilities and suitability for their project. This proactive approach demonstrates Nordstar Medical’s commitment to finding the optimal solution for their unique needs.

 

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The Challenges of High-Resolution Medical Device Prototyping

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The medical device industry demands unparalleled precision and quality. Nordstar Medical needed these super small parts for their core product functionality, as they are developing a medical device, specifically a catheter for nerve blocks. Prototyping this functionality was critical to validate their concept and discuss mass manufacturing with potential partners. The initial challenges were multifaceted: they attempted to print prototypes in-house using an SLA printer, however, the quality was insufficient to meet their needs. On the other hand, existing suppliers struggled with the intricate details and fine features of their design. The miniature scale of the components presented considerable difficulties, and these issues underscored the need for a supplier that could reliably produce parts with exceptional accuracy.

 

 

​​​​​Why NanoVoxel Stood Out: A Partnership, Not Just a Transaction

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In the opinion of Dr. Wraber, several factors set NanoVoxel apart from other providers. Firstly, NanoVoxel demonstrated a deep understanding of Nordstar Medical’s needs as a startup. It wasn’t simply a transaction, but a collaborative process based on flexibility and responsiveness. The dialogue between the two teams involved iterative design refinements: the initial prototype had weaknesses, which were addressed through collaborative problem-solving and material adjustments. Secondly, NanoVoxel understood the financial realities of a startup. They worked to optimize the prototyping process to align with Nordstar Medical’s budget constraints. This collaborative approach fostered trust and mutual respect, solidifying the partnership.

 

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Addressing Technical Challenges Through Ultra Rapid Prototyping

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Nordstar Medical’s design incorporated incredibly small features, measuring around 0.1 mm. These minute details were exceptionally difficult to produce with traditional tooling or standard workshop equipment. This is where NanoVoxel’s expertise proved invaluable: NanoVoxel’s 2PP 3D printing technology allowed Nordstar Medical to rapidly prototype and test various design iterations. The ability to produce numerous prototypes quickly was key to validating their concept and ensuring it worked as intended. Over 150 components were produced within days, and rigorously tested in animal tissue, dramatically accelerating the project timeline. This testing allowed them to compare different designs and identify the most effective design for their specific application. 

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​​​​​​​​​​​Communication and Support: A Crucial Element of Success

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Effective communication played a pivotal role in the project’s success. Dr. Wraber specifically highlighted the excellent collaboration with NanoVoxel’s dedicated Key Account Manager. They engaged in detailed discussions not only about the printed parts themselves but also about design for manufacturing, a vital aspect for mass production. This collaborative approach to design significantly improved the product and validated its feasibility for large-scale manufacturing.

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Conclusion: A Partnership for Innovation

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The collaboration between Nordstar Medical and NanoVoxel demonstrates the power of ultra high-precision micro-manufacturing in streamlining the medical device development process. NanoVoxel’s technological capabilities, combined with its collaborative approach and understanding of the client’s needs, played a crucial role for Nordstar Medical. The partnership led to faster prototyping, reduced costs, increased confidence, and faster time-to-market.

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