Medical therapy helmet SLA biocompatible prototype.
Case study: SLA 3D printing of a medical therapy helmet prototype in biocompatible photopolymer for a Melbourne medical device startup — patient-specific geometry from CT data, with internal sensor mounts and ergonomic surface finish.
Project overview
ASTCAD partnered with a Melbourne medical device startup to produce a patient-specific therapy helmet prototype. The geometry was derived from CT scan data, processed through 3-matic for surface treatment, and printed via SLA in biocompatible photopolymer with internal mounts for monitoring sensors.
The challenge
The helmet had to fit a specific patient’s head geometry with millimetre accuracy, integrate non-contact sensors, and maintain biocompatibility per ISO 10993 for skin contact. The prototype needed to be production-representative for the customer’s regulatory submission preparation.
Our approach
- CT data segmentation and surface meshing in Mimics + 3-matic
- Internal cavity design for monitoring sensors and wiring channels
- Material selection — biocompatible photopolymer per ISO 10993-1
- SLA print orientation for surface finish on skin-contact surfaces
- Post-cure protocol per medical-device prototype standards
Deliverables
- Patient-fitted prototype helmet (post-cured, finished)
- Manufacturing dossier suitable for regulatory submission
- Material biocompatibility documentation
- Design files in STEP and STL formats
- Recommendation for production manufacturing path
Outcome
The prototype was used in patient fitting trials and supported the customer’s TGA submission preparation. The customer has since commissioned a second iteration with updated electronics integration and is progressing through the regulatory pathway.