
FEATURED CASE STUDY
Live prototyping to help you get to market faster.
Accelerating Medical Device Development via Live Prototype Iterations
CDMOs promise rapid prototyping, knowing medical device manufacturers value speed in product development and time to market. Rapid prototyping can help accelerate development timelines, test designs, and iterative improvements — ultimately accelerating time to market.
“Customers often come to us having already identified a problem somewhere out in the field. They know what’s happening in the market and how many people need a particular type of surgery or procedure. We’re solving for a particular application and already understand the direct benefit to patients.”
CRAIG HERRON
Elevaris Engineering Manager
Better than industry-standard rapid prototyping, Elevaris Medical Devices offers the XLerator live prototyping program, where the team invites customers to share their facility and utilize a development environment within the company’s manufacturing space.Throughout this accelerated experience — lasting anywhere from 1⁄2 day to five days — Elevaris provides a complete team of technical support, including project engineers, process development engineers, manufacturing technicians, and machine operators.The offering also includes access to all the company’s manufacturing process technology and inspection capabilities.
Elevaris Medical Devices introduced its XLerator program nearly a decade ago after realizing the benefits to device developers via close onsite collaboration in its technology centers.
As part of the process, customers provide either a first-iteration design or rough idea for their device assembly prior to arrival at their XLerator Day. Upon their arrival at the live prototyping session, Elevaris engineers have the first actual parts ready for customers to evaluate or test in their devices.
“The key is that every project is different, but with factory-wide access, CAD programs, machining, cleaning, and inspection, we can help customers significantly streamline the ‘rinse and repeat’ rounds of prototyping as they typically know them. We test parts live on the table, and we’ve transformed into a single day what used to take weeks or months.”
JAMES BATE
Elevaris Engineering Manager
With a ready part, the customer can quickly determine minor changes required to improve performance.The Elevaris team converts the requested changes into a new manufacturing program, or process parameter change, and immediately produces improved designs.
As part of the XLerator program, customers get to see and share manufacturing processes — helping them more readily understand what is achievable and which modifications could lead to solutions. Depending on the process and design complexity, Elevaris can usually turn between four and eight design iterations in a single day.
In a particular instance, Surgin Inc., an engineering development company based in the United States, needed assistance in solving for flexibility in tubing.Where the customer originally incorporated a straight tube into its device design, the team discovered the need for a more flexible tube size to enable manufacturability. Based on the discovery, the engineering team was able to devise a more appropriate design.
In a satisfaction survey, the customer specifically lauded the knowledge and expertise of Elevaris engineers, availability of services and concierge-like approach to development, which “significantly streamlined our process.”
The participants went on to say,“We saved countless hours during our two days with the XLerator team.They were wonderful in preparing samples for our visit and flexible with our changing requests.Their openness about processes and insights into what would work best for our project needs was greatly appreciated. Specifically, the engineering and technical support on the laser cutting and welding machines greatly accelerated our development. It's clear why they are the go-to firm for both small and large companies developing new products.”
THE BENEFITS OF THIS APPROACH ARE SIGNIFICANT.
LIVE PROTOTYPING provides customers with:
Direct connection to CDMO engineers and direct access to the technology and development process, helping them understand the viability of the project and its potential delivery earlier in the development program
An expedited product development timeline, because wait times are condensed
Complete visibility into the manufacturing process, helping them understand design opportunities and constraints more quickly
Reduced development cost
Accelerated time to market
LASER CUT TUBE
Live prototyping enables several iterations of custom shapes, connection of tubes at specific angles, or formation of intricate geometries in a single session. It helps medical device engineers make immediate modifications, such as the laser cut tube with a puzzle cut shown above, condensing the development process by weeks or months. Direct access to Elevaris technology and complete visibility into the manufacturing process lets device engineers quickly understand design constraints, turn improved design iterations, and move product to market faster.

READY TO SEE WHAT’S POSSIBLE?
Elevaris XLerator Days provide medical device developers the ability to deliver precision solutions via a collaborative experience with deeply knowledgeable, trusted experts and extensive manufacturing capabilities.
Customers participating in XLerator Days consistently provide superior survey rankings regarding:
TECHNICAL SUPPORT AND CAPABILITIES
PROJECT COMMUNICATION
QUALITY OF SAMPLES
SPEED OF RESPONSE/ITERATION
ACHIEVEMENT OF PROJECT OBJECTIVES
SERVICE VALUE