Case Study: Opus KSD brings an innovative surgical stapler to market with Protolabs

Digital Manufacturing Helps Medtech Company Revolutionise Surgical Stapler

Opus KSD, a Massachusetts-based medtech company, sought to revolutionize surgery by developing a new tool, the SubQ It! skin closure system, which would combine the speed of a surgical stapler with the healing benefits of subcutaneous, bio-absorbable fasteners. The challenge was to design and prototype this complex multi-part device before committing to final production tooling, requiring high-precision parts to test form, fit, and function.

Vendor Protolabs provided a solution utilizing their CNC machining service to produce precise prototype parts for the stapler, which were designed as if for molding to validate the design. After successful testing and refinement, Protolabs then manufactured the final production parts via injection molding. As a result, the SubQ It! system gained FDA approval, successfully launched to market, and Protolabs continues to help Opus KSD scale up production to meet rising demand for the product.

Opus KSD

Chuck Rogers

Chief Executive Officer, Biomedical Engineer