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How 3D Scanning and 3D Modeling was used to Create a Custom part for a Medical Device.

Updated: 3 days ago

It started out as a problem. For Joel Rosenberg, he needed a way to fix his laser hair removal instrument. He had an idea but needed some help turning his idea into an actual functional product. This involved 3D scanning the existing laser hair removal device and engineering a custom fit case that could also accommodate a skin cooling device. He had previously been using velcro to attach these two pieces together, but this was not working.



In order for the hair removal laser to be kept cool, it would require a precise amount of air being circulated towards the front of the device. We needed a way to mount the air tube to the device securely and precisely, ensuring the laser wouldn't overheat.



We utilized multiple 3D technologies to help create a unique mount for the device that would keep the airflow consistent and aligned properly.


The first step was to capture a high resolution 3D scan of the hair removal laser. Once we had the device digitized, we could then import the digital asset into 3D software and begin to model the prototype part digitally around the scan of the original device. Getting an accurate scan was imperative, since we were using it as the basis to model the mount for the airflow device. The fitment had to be very precise. Otherwise, it would not allow the laser to function properly. Once our design was finalized digitally, we could then 3D print a physical prototype.


We were able to quickly 3D print multiple prototypes in order to test fit the part onto the existing device. This allowed us to make sure the fitment/design was perfect before 3D printing the final part in a more durable material. After the test fitting, we had to make some minor changes to the design. Using 3D software and having already created the part digitally allowed these changes to be made quickly.


We tried several different renditions:





But, we ultimately settled on one:

We 3D printed the final part in nylon, which is much more durable and offered more flexibility. This was needed in order to get the device mounted sturdily. All in all, combining these technologies allowed for a faster and more cost effective way to produce a custom functional part. This workflow can be applied almost endlessly, as it is a valuable tool set suited for a huge variety of industries.


Now Joel can get back to work. This unique device allowed him to run a more efficient laser hair removal business with more satisfied hair removal technicians and more satisfied customers.

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