One of the exciting aspects of engineering is the potential to design and build something that truly revolutionizes the quality of life for the better. Fillauer Composites uses carbon-fiber and fiberglass to build prosthetic feet. When needed to perfectly produce carbon fiber parts, Fillauer partnered with 3D Hubs to reduce the cost of production and open up more time for their engineers to focus on perfecting the designs. Medical device technology is a field at the center of innovation. With the constant availability of new materials and designs, medical device manufacturers are always finding ways to make products that are durable, easy-to-use, and improve the end user’s lifestyle.
About Fillauer and Prostheses
The parent company of Fillauer Composites was birthed in 1914. From creating metal braces for backs and legs, Fillauer LLC has evolved into a producer of state-of-the-art prosthetic limbs and ankle foot orthoses. Fillauer Composites is a 21st-century subsidiary that focuses on prosthetic feet made from carbon fibers. Working with these thin crystalline filaments calls for intricate processes that respect the integrity of the material. Constantly soliciting feedback from amputees, clinicians and designers, staff at Fillauer are charged with taking these perceptions and delivering improvements in design.
To respond promptly and effectively to this input, the company is pressed to come up with prototypes–made from alternative materials–in ways that are not too expensive and respect the time of its manufacturing department. While production with carbon fiber does not seem so unique on the face of it, errors may not evidence themselves until near the end of the process. Tracing the source of the problem can be a vexing task. The detection and correction of such flaws is why manufacturers opt to prototype parts prior to full-scale production. Yet the demand for prototypes can put a strain on manufacturer capacity.
Enter a Partner
The relatively young technology of 3D printing helps to expedite prototype creation, especially with regard to minute test components. Fillauer solved its time and expense dilemma by turning to 3D Hubs, an on-demand distributor of prototypes and production parts. Employing manufacturing affiliates all over the globe, this company operates a 3D printing service that delivers with punctual turnaround times. Fillauer also relies on the worldwide distributor for production parts. Brackets, for instance, that aid in the joining of prosthetic foot to the socket are supplied by 3D Hubs injection molding unit. The company also specializes in CNC machining as well as its 3D printing service.
Like all relationships, the Fillauer Composites connection with 3D Hubs is a work in progress. Yet the Fillauer people appreciate the ease with which their partner receives and transmits evaluations and recommendations. Online 3D printing might seem impersonal, but never in a business where close communication is essential to a quality finished part. In the end, uploading designs to this responsive 3D printing service is a boon for Fillauer, simplifying the process and forging strong relationships.
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