Case Study: SonoWand achieves small‑series, high‑quality production of its real‑time brain scanner with Materialise

Sound Advice for Redesigning a Small Series Brain Scanner

SonoWand, working with design partner Creo Development, needed to redesign its real‑time brain scanner — a high‑end medical device with a new fluent form and a single 24" touchscreen — for a small production run of about 50 units per year. Faced with strict durability, aesthetic and cost constraints for a surgical environment, they engaged Materialise for manufacturing advice and low‑volume/additive manufacturing solutions.

Materialise proposed a mix of technologies tailored to each part — RIM for smooth, paintable monitor and top covers with metal inserts and honeycomb ribs to cut weight and boost strength; stiff TPE injection‑moulded bumpers; vacuum‑cast UV‑resistant probe holders with alumide laser‑sintered inserts — delivering durable, high‑quality components and a high‑gloss finish. Materialise’s approach enabled production of the 50 units/year small series while avoiding expensive tooling and investment risk, improving durability and manufacturability for market launch.

SonoWand