Timely Prototype Manufacturing for Medical Covers
iThera Medical: How the medical technology company was able to reduce costs and meet accelerated deadlines successfully with the formary supplier network.
About iThera Medical
iThera Medical is a leading medical technology company specializing in high-resolution photoacoustic, non-invasive imaging technologies. With its innovative multispectral optoacoustic tomography (MSOT), iThera Medical enables real-time visualization and quantification of biomarkers such as hemoglobin in blood or collagen in muscle, which vary in certain medical conditions. This technology significantly contributes to improving patient care in the field of medical research.
Watch the case study video and find out how iThera Medical was able to benefit from the B2B platform formary.
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💡The deep-drawing project with iThera illustrates how formary takes on projects with demanding requirements, including tight schedules, small-volume material procurement, and complex post-processing steps. The result: The client can relax knowing that formary handles all requirements, ensuring that all specifications are met through its powerful supplier network.
Project Overview
- Project goal: 50% reduction in costs and volume for the new device generation
- Challenge: Tight deadlines, material shortages, and stringent medical requirements
- Solution: Coordination of multiple specialist manufacturers within the formary network
- Result: On-time production of visually and qualitatively high-end housing components
The Problem
A new generation of devices offering a 50 per cent reduction in costs but meeting high medical standards
iThera Medical had set itself the task of achieving a 50 per cent reduction in the cost and volume of the platform for the new generation of MSOT Frontier devices, without compromising on quality or design. The requirements for plastic trim components in the medical sector are high and were in direct conflict with the cost-reduction target:
- Fire protection in accordance with the UL94-V0 standard is required
- Scratch-resistant surfaces and resistance to cleaning products
- Protection against electromagnetic radiation (EMC shielding)
- UV protection for long-term stability
- A reliable means of ventilating the electronic components
- A clean, immaculate and outstanding appearance for medical practices and hospitals
- Gap-free fitting to the unit with complex milled features
This combination of technical, medical and aesthetic requirements made the development a challenging project.
The Challenge
Bringing forward external tests is putting the timetable and the procurement of materials under severe strain
The housing for the new generation of MSOT devices had to meet all medical requirements whilst halving the costs. The challenges of the project were clearly defined:
✓ A 50% reduction in costs as a binding project target
✓ Very tight deadlines due to external verification tests (EMC testing) being brought forward
✓ Corresponding shortage in the availability of the special ABS/PC blend UL94-V0 material
✓ Complex milling operations for ventilation balancing and gap-free installation
✓ Multi-stage finishing (CNC milling, textured paint finish on the outside, EMC paint finish on the inside)
✓ Small quantities and samples for the prototype phase
Torsten Parth of iThera Medical explains: “Due to an external verification test being brought forward – specifically an EMC test – we found ourselves in urgent need of housing components that could be approved at short notice.”
The Solution
Design- and network-based optimisation through material allocation and the coordination of three specialist plants
Based on the initial design drafts, formary developed a series of further proposals aimed at achieving a more efficient and cost-effective production of the housing components. In doing so, all key aspects were assessed in terms of their cost-benefit ratio:
✓ Material selection and procurement costs
✓ Design of thermoformed parts with regard to necessary milling, trimming and assembly elements
✓ Tool design for aluminium or alternative material
✓ Material thicknesses at the exit from the perspective of tool design
✓ Impact of the factors on the delivery schedule and its manageability
The consultancy involved detailed recommendations regarding the optimal choice of materials, including specific material thicknesses, which were selected taking into account mechanical requirements and costs. The result was the design of three optimised, aesthetically high-quality housing components, which, through their paint finish, provided EMC shielding, ensured UV protection and UL94-V0 flame retardancy, and enabled the ventilation of the electronic components and the CPU.
A critical hurdle
Material shortages at the primary supplier
Due to the tight schedule, the specialist manufacturer originally selected by formary was unable to source the required specialised material in time. It seemed impossible to arrange delivery of the finished and post-processed parts, including milling and external painting.
Network solution: Three businesses, one goal
In this critical situation, formary drew on its extensive network of suppliers and coordinated three specialist companies:
Plant 1 (alternative source of material):
✓ Had the required special material, ABS/PC blend UL94-V0, in stock
✓ Provided materials at short notice
✓ Took on the deep-drawing of a less complex component
Company 2 (Original Specialist):
✓ Received materials and pre-assembled parts from Plant 1
✓ Focused on more complex components requiring specific manufacturing techniques
✓ Carried out CNC milling and finishing work
Plant 3 (painting specialist):
✓ Completed final structural paint finish in RAL 9016 on the exterior
✓ Carried out EMC coating on the interior
✓ Ensured high-quality surface finishing
Thanks to this coordinated collaboration between various specialists, the project was successfully completed on schedule despite the initial problems with sourcing materials.
The Advantage
The supplier network as a lever for speed and quality in the event of material shortages
Thanks to the flexible orchestration of the formary supplier network, iThera Medical gained key advantages:
✓ Access to alternative sources of materials in the event of shortages
✓ Deep-drawing, milling and painting carried out simultaneously by specialist contractors
✓ Regular status updates throughout the project coordination process
✓ Relieving the customer of logistical complexities
✓ Focusing on other challenges in product development
The result: iThera Medical was able to focus on core development, whilst formary took charge of coordination and management.
“When we approached formary, the initial focus was on prototype manufacturing, which was to be transferred into series production after various approval processes. Since the process wasn't finalized, we first submitted several designs for feasibility testing in thermoforming with formary.”
— Torsten Parth, iThera Medical
The Result
On-time delivery, successful verification and prototype roll-out
The three housing components, developed jointly, were delivered to iThera Medical on schedule following quality checks. The initial internal and external tests, as well as the general roll-out of the prototype at iThera Medical, were successful.
The following factors were crucial to the project’s success:
✓ Design optimisation from a cost-benefit perspective
✓ Flexible material procurement through network access
✓ Coordination of three specialist firms to ensure parallel processing
✓ Continuous quality management across all stages of production
✓ On-time delivery despite external verification tests being brought forward
Torsten Parth confirms: “It was crucial for us to receive the fully manufactured parts on time and to be able to fit them directly into the prototypes. Ultimately, thanks to the sophisticated quality management system, we received flawless housing parts with precise tolerances and an excellent finish.”
FAQ – Frequently Asked Questions About Medical Housing Projects
formary supports medical technology companies from feasibility analysis and prototyping through to series production. The supplier network enables fast and efficient workflows.
Further Information on Medical Housing Components
Medical Housing Components in Theory and Practice
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We show you for which production volumes, sizes, and geometries the thermoforming process is ideally suited for medical housings—functionally, visually, and from a cost–benefit perspective.
Medical Housing Components in Plastic Thermoforming
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Learn why plastic thermoforming is gaining relevance in medical technology and what medical device manufacturers should know about the possibilities of thermoformed plastic housing components.
Surface Finishing for Medical Housings: Function Meets Design
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Discover how thermoforming, while meeting regulatory requirements, can be used to manufacture medical housings that are both visually appealing and highly functional.
