Case Study: Potomac Photonics achieves high-precision micro 3D printing of middle-ear prostheses with 3D Systems' ProJet 3500

Micro 3D Printing Middle Ear Prostheses To Bring Music to the Ears of Hearing Loss Sufferers

Potomac Photonics, a micro-manufacturing specialist, was enlisted to produce the tiny components of a middle-ear stapes prosthesis developed by researchers at Warsaw Technical University to treat otosclerosis — a common, lifelong cause of hearing loss. The challenge was to produce extremely small parts with very tight tolerances for experimental implantation and mechanical verification, something earlier 3D printing methods could not achieve.

Using the 3D Systems ProJet 3500 MultiJet printer with 32-micron layer resolution and a range of durable materials, Potomac delivered highly accurate micro‑printed prototypes with quick turnaround, even for international shipments. The parts met the required geometries for testing, enabling rapid design iteration, making short production runs economically viable and advancing the development of implantable stapes prostheses that could restore hearing for many patients.

Potomac Photonics