Case Study: Medtronic achieves rapid, durable functional prototypes with Stratasys FDM

Medtronic Utilizes Stratasys 3D Printing Solutions For Medical Tools, Functional Prototypes Improve Design

Medtronic–Sofamor Danek, a world leader in spinal and cranial medical technologies, faced the need to quickly turn surgeon ideas into tough, sterilizable working prototypes for rapid evaluation. To meet fast turnaround and durability requirements, they adopted Stratasys Fortus FDM (fused deposition modeling) rapid prototyping technology in their in‑house lab.

Using Stratasys Fortus FDM, Medtronic engineers produced polycarbonate functional prototypes—most notably a ratcheting counter‑torque instrument—that could be autoclaved and delivered to surgeons the same day or next morning. Real-world testing at three hospitals led to a handle‑rotation design change, reduced miscommunication, faster iteration cycles, and measurable cost savings from cutting outsourcing and refining designs before expensive metal fabrication.

Medtronic

Troy McDonald

Senior Engineering Manager