When one of Germany’s leading pharmaceutical manufacturers chose Stansomatic as a partner, the journey from design to prototype became a story of efficient collaboration, meticulousness and technical expertise.
This case study highlights how a structured approach and continuous optimization contributed to developing specialized metal components for electrosurgical devices.
From idea to finished product
A customer developing and manufacturing surgical instruments and medical devices for surgeons, operating rooms, and patients worldwide needed contacts and electrodes for some of their advanced electrosurgical devices.
Stansomatic’s task involved:
- Optimizing designs and components
- Utilizing advanced technology and technical expertise to manufacture the components
- Adhering to extremely tight tolerances
The first contact occurred at a trade fair in Germany, where a mechanical engineer from the customer’s development team was introduced to our solutions. Having previously worked with suppliers who abandoned the project due to its complexity, the customer sought a partner capable of handling the challenge. Within just a few weeks, the project officially began.
A flexible collaboration
Our technical team collaborated closely with the customer’s engineers to develop an optimal setup. We leveraged specialized expertise, including prototype manufacturing, to create components that not only met stringent tolerances and surface roughness requirements but also ensured high reliability and durability. The customer had specific demands regarding material selection and surface treatment to ensure the components could withstand challenging environments and meet strict hygiene standards.
Throughout development, we had multiple collaborative meetings with the customer’s development team to continuously refine design and production. This flexible approach enabled us to quickly implement changes and optimize the components. Transparent communication and swift responses ensured both functionality and production efficiency were maintained throughout the process.
Result: an efficient and durable solution
We used technologies such as deep drawing and laser cutting to develop a prototype setup, which was ideal given the low annual volumes of the components.
The first component is an electrode that delivers electricity to the product. Our optimization proposals improved the design, ensuring it fits seamlessly into the overmolding process.
The second component is a contact designed to fit into a circuit board for an advanced electrosurgical instrument used in surgeries worldwide.
The customer praised our problem-solving approach and commitment to finding solutions aligned with their interests, which played a significant role in selecting Stansomatic as their partner.
By resolving the customer’s challenges, Stansomatic enabled seamless mold testing and supported the development of an entirely new medical instrument.
Søren is ready to answer all your questions
We are more than a supplier of stamped parts: With Stansomatic you get an integrated partner that takes responsibility for the entire process from start to end.