WayKen Supports Heart Simulator Prototyping for Medical Development

Product Background

Cardiovascular diseases are a major global health challenge, causing a heavy burden on healthcare systems. With lifestyle changes, unhealthy diets, and less exercise, these diseases are on the rise. That’s why it needs more innovation and technology support to help lower cardiovascular disease rates and improve public health.

Our customer, a leading international medical device company is driving innovation in cardiovascular health by focusing on advanced technologies. They wanted to develop high-precision medical devices to improve treatment for heart disease patients. To do this, they planned to make a cardiac blood simulator that realistically mimics blood flow in the heart. This tool will not only help train doctors in surgeries but will also be used to test new devices.

About the Project

In product development, the heart blood flow simulator required the use of CNC technology for prototyping and part production to ensure design accuracy and functionality. Our customers also wanted to accelerate the development process and bring them to market faster. Therefore, they found professional machining support from WayKen to achieve these objectives.

Actively Respond Before Production

In the early stages of the project, WayKen connected with the client’s procurement department to gather basic information and initial drawings. During the review, our project manager noticed that the drawings were incomplete, and the assembly relationships between parts were unclear.

To keep the project on track, we held detailed discussions with the client to clarify these ambiguities. After organizing and confirming all necessary information, we promptly prepared a machining solution and submitted it to the customer. Once approved, WayKen immediately moved into production.

Processing Challenges and Solutions

While good communication at the start helps keep the project on track, challenges can still appear during the actual manufacturing process.

Diversity of Parts

This cardiac blood simulator required a wide variety of prototype parts made from different materials and using various processing technologies. For example, we worked with PC materials, photosensitive resins, brass, and stainless steel, employing methods such as CNC turning and milling and 3D printing.

This complexity introduced challenges in coordinating multiple manufacturing processes while maintaining high precision and consistency. Each material required specific processing techniques, and the variety of components demanded careful planning to optimize production efficiency.

To address these challenges, the WayKen team developed detailed processing strategies tailored to each material and manufacturing method. We optimized production workflows to ensure efficient sequencing and minimized the risk of errors. Strict quality control was implemented at every stage, ensuring each part met the required specifications.

PC Board Bonding and Sealing Requirements of the Simulator Prototype

The simulator’s design required bonding two PC boards to meet functional requirements. Initially, UV glue and acetone were considered as bonding materials. However, after thorough testing, WayKen found that UV glue could block critical internal channels essential for functionality. To avoid this issue, the engineering team chose acetone bonding, ensuring reliable sealing without obstructing these channels.

To ensure precision and consistency in the bonding process, WayKen developed a detailed bonding guide and conducted specialized training for operators. This approach minimized errors and maintained high-quality standards throughout the process.

Assembly of CNC Parts and 3D-Printed Parts for Simulator

Achieving a precise fit between CNC-machined PC parts and 3D-printed components was crucial for this project. Any misalignment could cause structural instability or functional issues, affecting the cardiac blood simulator performance.

To overcome this challenge, WayKen designed custom fixtures and followed detailed drawing to ensure accuracy and a proper fit for each component. During CNC machining, trial assemblies with 3D-printed parts were conducted to identify and resolve any fitting issues quickly. Additionally, the QC department carried out rigorous quality checks at every stage, guaranteeing consistent accuracy and reliable assembly.

Clarifying Finishing Requirements

In the post-finishing stages of heart blood flow simulator part production, WayKen identified the need for clarification on the polishing requirements for the plastic parts and the paint color specifications for the 3D-printed components. To resolve this, the team organized multiple video conferences with the client’s technical staff. These direct discussions helped clarify engineering details and address any business-related questions.

WayKen prioritized through collaboration and attention to detail, ensuring the project progressed smoothly. In addition to providing technical support, we focused on delivering high-quality service throughout the partnership, fully supporting the client’s product development needs.

Feedback

The client expressed high satisfaction with WayKen’s support in developing the cardiac blood simulator. They appreciated WayKen’s quick response during the initial communication phase, accurate understanding of their requirements, and effective problem-solving approach. This contributed to improved production efficiency and a successful project outcome.

WayKen specializes in prototyping and low-volume production, offering CNC machining, 3D printing, and rapid manufacturing solutions for medical and other industries. With expert engineering support and strict quality control, we help bring innovative products from design to reality. Partner with WayKen for reliable and efficient prototyping and machining services.