Large-Scale Additive Manufacturing for a Leader in Medical Equipment

Delivering Trade-Show-Ready Medical Equipment in a Hurry

When a well-known name in the medical equipment field needed full-scale MRI patient tables and docks for the Radiological Society of North America’s annual trade show, the challenge was clear. The parts had to be visually flawless, structurally sound, and delivered on a non-negotiable deadline.

Traditional manufacturing methods were not an option. The size, complexity, and timeline demanded a manufacturing partner with proven experience in large-format additive manufacturing and medical device prototyping, so they turned to Evology Manufacturing.

The Challenge

The project scope was ambitious from the start. Evology was tasked with producing two fully functional MRI patient tables and docking systems for a high-visibility trade show appearance. Each table measured over nine feet long, with individual sections reaching up to twenty inches thick.

In total, the project required more than thirteen thousand cubic inches of printed material. The components were too large to print as single pieces, requiring multiple bonded sections while maintaining structural integrity and a smooth finished appearance.

Additional challenges with the print included:

• Maintaining durability while keeping the assemblies lightweight for transport and setup
• Routing internal electronics for a movable table and illuminated operator interface
• Ensuring all parts were ready, assembled, and finished well ahead of the show floor deadline

Most critically, the entire build needed to be completed under extreme time pressure.

The Additive Manufacturing Approach

Evology selected FDM additive manufacturing as the ideal process for this application. Using five Stratasys Fortus 900 systems running a 0.020 in. (0.5 mm) nozzle, the team printed all components in ASA, chosen for its strength, surface finish, and suitability for large-scale medical device structures.

FDM allowed Evology to produce complex internal geometry, lightweight structural sections, and integrated pathways for electronics without the cost and lead times associated with traditional tooling.

Printing was completed in just fourteen days, followed by five days of paint, finishing, and final assembly. Despite the scale of the project, Evology delivered the parts ahead of schedule.

Execution at Scale

Because the parts could not be printed in single pieces, Evology engineered the assemblies with precise bonding joints designed to maintain strength while leaving no visible seams. Post-processing included machining critical interfaces, surface finishing, and paint to meet the expectations of a public-facing medical device display.

Throughout the project, Evology maintained close communication with the customer, providing regular status updates and proactively addressing design and assembly challenges as they arose. With reliable progress at every stage, the customer could plan the rest of their show preparation with confidence.

Measured Results

The finished MRI tables and docks met all functional, visual, and structural requirements. The assemblies were durable enough for repeated handling, lightweight enough for easy movement, and visually polished for a high-profile trade show environment.

Key outcomes included:

• Successful delivery ahead of the trade show deadline
• Full-scale medical equipment produced entirely through FDM additive manufacturing
• Integrated electronics and operator interface features
• Additional project support beyond the original scope thanks to early completion

Most importantly, the customer reported that Evology removed stress from a critical phase of the project by delivering reliable communication, consistent progress, and dependable execution.

Why It Matters

This project demonstrates what is possible when large-format FDM additive manufacturing is applied to real-world medical equipment challenges. Additive manufacturing is not limited to small prototypes or concept models. At scale, it enables rapid production of functional, durable, and visually refined components that would otherwise require months of traditional manufacturing lead time.

For medical device teams preparing for trade shows, product launches, or system demonstrations, additive manufacturing offers flexibility, speed, and design freedom without compromising quality.

Moving Forward

Evology Manufacturing continues to support medical device companies with advanced additive manufacturing solutions, from rapid prototyping to full-scale functional assemblies. To see how large-format additive manufacturing can accelerate your next project, explore our medical manufacturing and FDM capabilities.