Combined 3D Services

3D Printing for Medical Devices: Prototyping, Surgical Models, and Custom Instruments

Posted on by Shelle Parsons

By Mike Moussa, PE — Medical device development has unique requirements. Here’s how 3D printing fits into the medical product development lifecycle.

Medical Applications We Support

Pre-Surgical Planning Models

3D printed anatomical models from CT/MRI scan data. Surgeons can hold, examine, and plan procedures on a physical replica before entering the OR. Studies show pre-surgical models reduce operating time by 20-30% and improve outcomes.

Medical Device Prototyping

Iterate on your device design in days instead of months. 3D printing lets you test ergonomics, assembly, and basic function without tooling investment. Critical for investor presentations and early user feedback.

Custom Surgical Instruments and Guides

Patient-specific surgical guides, drill templates, and cutting jigs. Designed from imaging data, printed in sterilizable materials, used once for precise surgical execution.

Veterinary Bone Models

Same concept as human surgical planning, applied to veterinary orthopedics. We’ve printed bone models for complex fracture repairs and joint replacements in dogs and horses.

Dental Models and Aligners

High-resolution SLA printing produces dental models with the precision required for aligners, crowns, and bridges. Smooth surfaces, accurate margins, and consistent quality.

Materials for Medical Applications

  • Biocompatible resins (SLA) — USP Class VI certified for limited skin contact. Suitable for surgical guides and short-term contact devices.
  • Autoclavable materials — ULTEM and certain Nylons can withstand autoclave sterilization (134°C/275°F).
  • Flexible resins — Simulates soft tissue for surgical planning and training models.
  • Multi-color/multi-material — PolyJet technology creates models with different colors for arteries, veins, tumors, and bone in a single print.

Regulatory Considerations

We’re transparent about what we can and can’t do:

  • We build prototypes, models, and development devices — not production medical devices
  • For 510(k) or PMA submissions, we work with your regulatory team to document materials, processes, and quality controls
  • For surgical models used in planning (not implanted), regulatory requirements are minimal
  • For production medical devices, we help you develop the design and then connect you with FDA-registered contract manufacturers

Working with PartSnap

We sign NDAs before seeing your device. We understand HIPAA requirements for patient data (imaging files). And we work within your development timeline — whether that’s a 2-week sprint or a 2-year FDA pathway.

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