Amedical-device manufacturer uses rapid prototyping to develop noninvasive electrotherapeutic equipment. The devices treat pain and swelling by stimulating a patient's anti-inflammatory response with electromagnetic pulses. The business of Ivivi Technologies, Montvale, N.J., (ivivitechnologies.com) frequently calls for small quantities of different devices for clinical trials.

“We previously relied on job shops for prototypes, but they took months to generate a prototype,” says Ivivi's Board Chairman Andre A. DiMino. “And the part, of course, usually needed several revisions to get it right for clinical trials. So we needed a faster method that would let us perform engineering, development, and production in-house.”

DiMino's team selected the Eden350, a 3D printer from Objet Geometries Ltd, Billerica, Mass. (objet.com) because it prints lightweight, durable parts with smooth finishes. “We got a positive return on our investment in less than a year,” says DiMino. “The machine cuts an average of five to six weeks off production. And it lets designers make product changes overnight. The machine also provides a rapid, cost-efficient way to build custom production tools such as jigs and fixtures to hold the devices.”

DiMino's team is now considering upgrading to an Objet machine that simultaneously builds with several materials, each with different mechanical properties. DiMino says the machine should let the company further streamline the production of devices consisting of rigid electronic casements and softer components for patient comfort.