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3D Printing for Medical Technology ready for Series Production

3D Printing Space Savers for Medical Technology

STORZ MEDICAL uses 3D-printed, flow-optimized air distributors in the handpiece for its Masterpuls shock wave therapy device. In collaboration with 1zu1scale, over 50,000 parts were manufactured and the original two-part component was converted into a single-part, high-precision series solution.

Thanks to our in-house expertise combined with the latest technologies, we increase security for our customers and also reduce the amount of internal testing required.

Philipp Schelling,Production Manager 3D Printing & Vacuum Casting

Complex Air Distribution in the Masterpuls Handpiece

The compact air distributor performs the central task of air flow in the handpiece of the Masterpuls shock wave therapy device - a decisive factor for the performance and reliability of the device, which is used worldwide to treat pain in the musculoskeletal system. The flow-optimized 3D-printed geometry has enabled the implementation of integrated functions that would not be possible with conventional manufacturing processes. The new one-piece solution reduces additional parts, minimizes assembly effort, and increases the density of the components through chemical smoothing.

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Components

New generation of components reduces parts and assembly time

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Properties

Pressure resistance up to 6 bar

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Scaling

> 60,000 air distributors manufactured in series production for Masterpuls

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Additional Services

Chemical smoothing and process control

SCALE: One Process, many Advantages

Sketch

Additive manufacturing considered from the outset

  • Holistic development of 3D-printed series parts
  • Use of additive manufacturing already in concept and prototyping
  • Ergonomic redesign of the handpiece with a focus on function and user comfort

Check

Iterative optimization for optimal geometry

  • Iterative optimization of component geometry
  • Solution to residual powder problems
  • Improvement of the flow-optimized design
  • Technical advancement from a two-part to a one-part design

Approve

Design simplified & finalized

  • Validated, one-part design with reduced number of components
  • Significantly lower assembly costs
  • Design freeze as the basis for stable series production

Launch

Series process established

  • Transition to series production
  • Use of a state-of-the-art EOS P500 SLS system
  • Establishment of chemical smoothing for surface and density requirements

Execute

Efficient series production with consistent quality

  • Series production with high density and efficiency
  • Reproducible quality across all batches
  • Market-ready product – additively manufactured, economical, and reliably scalable

A Result that is impressive

In collaboration with STORZ MEDICAL, 1zu1scale has developed a single-piece, high-precision 3D-printed air distribution component for the Masterpuls handpiece. The new solution cuts assembly time in half, reduces the number of additional parts, and meets the highest tightness and series production requirements—a milestone for additive manufacturing in medical technology.

We broke new ground and are now reaping the rewards of our conviction and perseverance. The project was a milestone. Since then, 3D printing has established itself as a manufacturing process for series parts.

Felix Gremlich,Head of Design at STORZ MEDICAL AG


Questions & Answers


It regulates the air flow in the handpiece of the shock wave therapy device and affects performance and reliability.

3D printing offers free form design, integrable functions, and the possibility of series production without tooling costs.

The one-piece design integrates the air outlet duct, reduces the number of parts, and shortens installation time.

SLS 3D printing with a modern P500 system followed by chemical smoothing.

Process parameter monitoring, automated post-processing, and high process stability ensure consistent quality.

Depending on the number of pieces and function, especially for internal components in device design.


Project Managers

From idea to series: The people behind the project.


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