Case Study: Coapt achieves rapid prototyping and additive production for next‑gen prosthetic hardware with Fast Radius

Improving an innovative medical device through additive manufacturing

Coapt, a Chicago-based maker of the COMPLETE CONTROL myoelectric pattern recognition system (an FDA class II medical device), needed to redesign hardware and accelerate development for its second-generation product. To meet tight release timelines and test many geometry, texture and aesthetic options, Coapt partnered with Fast Radius and relied on their additive manufacturing services, including Carbon® Digital Light Synthesis (DLS) and HP Multi Jet Fusion (MJF), plus Fast Radius’s additive engineering expertise.

Fast Radius delivered rapid prototyping, materials guidance and additive production for end-use parts, printing 36 unique designs and producing 195 prototype parts over 12 weeks to speed iterations and validation. Fast Radius also produced production components—such as calibration buttons and can plugs—using Carbon DLS with EPU 40 (high throughput builds: 135 buttons per 35-minute print, 848 can plugs per 23-minute print) and a PA 12 fabrication dummy via HP MJF, enabling Coapt to hit development milestones and move smoothly from design optimization to production.

Coapt

Blair Lock

Founder and CEO