Case Study: Bluefrog Design Ltd. achieves a life-changing custom medical device in 3 days with Stratasys additive manufacturing

Bluefrog Design Creates Life-Changing Medical Device with Stratasys Additive Manufacturing

Bluefrog Design Ltd., a small multidisciplinary industrial design consultancy, was asked to solve a unique medical challenge: create a custom, body-conforming wearable for a patient with paraesthesia that minimized skin contact and could be produced realistically and quickly. Traditional prototyping methods were too slow, costly and lacked the necessary realism, so Bluefrog turned to Stratasys and its additive manufacturing technologies (FDM®/Fortus 3D printing and ABSplus™ materials) for a solution.

Using Stratasys additive manufacturing, Bluefrog produced a detailed 3D scan, iterated a prototype on their Fortus FDM printer and delivered the final part in medical-grade ABSplus, leveraging lattice-based design to reduce weight and material use. Stratasys’ round-the-clock printing enabled a three-day turnaround and up to 60% material savings versus traditional methods, yielding a lightweight, personalized device that resolved the patient’s symptoms and demonstrated clear, measurable impact.

Bluefrog Design Ltd.

Chris Samwell