3D printing in series: 1:1 realization of over 50,000 multifunctional series parts for STORZ MEDICAL

1zu1 and STORZ MEDICAL realize compact, flow-optimized air distributors for a medical device through 3D printing. (Photo: Darko Todorovic)

3D printing allows for flow-optimized design and the integration of functions. (Photo: Darko Todorovic)

1to1 ensures even greater efficiency in production and post-processing through automated blasting systems. (Photo: Darko Todorovic)

The Dornbirn-based high-tech company 1zu1 is a global pioneer in the series production of high-quality components through 3D printing. Technological advantage, state-of-the-art equipment, and many years of experience already enable the manufacturing of market-ready parts with maximum flexibility and extraordinary geometric freedom. For a medical technology product from the renowned Swiss company STORZ MEDICAL, 1zu1 has produced more than 50,000 compact, flow-optimized elements via 3D printing.

Delicate structures, low weight, limited batch sizes, and a high degree of customization: The high-tech company 1zu1 meets the complex requirements of medical technology products with high-quality 3D-printed components, giving its customers a competitive advantage. "Toolless manufacturing, freeform design, the integration of functions, and the seamless transition from prototype to series save time, additional parts, development costs, and ensure confidentiality," emphasizes 1zu1 Managing Director Hannes Hämmerle. "We harness the full potential of selective laser sintering, have set new standards in process stability, and thus create more homogeneous parts than ever before," adds Managing Director Wolfgang Humml.

In a long-term project for the renowned medical technology company STORZ MEDICAL, 1zu1 produced over 50,000 two-part air distributors for a shockwave therapy device, paving the way for industrial series production via 3D printing. As an EOS development partner, the company possesses the latest and most powerful laser sintering systems and actively contributes to the further development of 3D printing. This is complemented by an advantage in finishing processes and increased efficiency and quality in post-processing and quality assurance.

Reference Project: Pioneering Achievement as an Innovation Driver

The design and batch size of the medical technology product are ideally suited for construction via 3D printing. The geometric freedom of the process allows for lightweight, space-saving, and flow-optimized components with integrated functions such as channels, undercuts, and chambers. The use of cutting-edge technology enabled the further development of the component into a single-piece solution. During this process, 1zu1 gained valuable practical experience over nearly two years through the exclusive use of the high-performance EOS P500 system. The fastest laser sintering system on the market, combined with optimized parameters, ensures the highest process stability and near 100 percent repeatability for series production.

Innovative technologies such as chemical polishing, automated blasting, and comprehensive quality control using computed tomography reduce process steps and increase the profitability of series manufacturing via 3D printing. "We rely on the latest available machines, continuously expand our portfolio, and optimize production processes. Our pioneering achievements and the trust of our customers drive innovation," says 1zu1 Operations Manager Christian Humml.