Injection molding series at a rapid pace: 1:1 scale produces medical technology components

The plastic components from 1zu1scale fit together perfectly and meet all the criteria for series production. (Photo: Darko Todorovic)

1:1 scale produced in injection molding three assemblies for the Mesh Inhaler Platform elaera® by Activoris. (Photo: Darko Todorovic)

1:1 scale produces high-quality series components for medical technology specialist Activoris through injection molding. (Photo: Darko Todorovic)

1:1 scale produces high-quality series components for medical technology specialist Activoris through injection molding. (Photo: Darko Todorovic)

Tobias Kolb and Axel Fischer from Activoris with the elaera® inhaler. (Photo: HTAI/bartels + drescher)

1zu1scale controls the housing made of plastic for the Mesh Inhaler Platform elaera® from Activoris. The handy system from the medical technology specialist based in Gemünden (Wohra) aims to simplify the intake of many medications. Six months after the start, 1zu1scale delivered three series-ready assemblies with a total of eight injection-molded components. The member of the Prototal Group supports the development process. With the secured quality, Activoris is taking the next step towards market launch.

With rapidly scaled series components made of plastic, 1zu1scale accelerates the market introduction of medical innovations. Activoris from Gemünden (Wohra) thereby saves time and costs in the approval process. The medical technology specialist is developing a standard solution for pharmaceutical and biotech companies with the Mesh Inhaler Platform elaera®. The compact device is intended to simplify medication intake and enable mobile therapeutic approaches.

1zu1scale manufactures three assemblies with a total of eight parts for the housing using injection molding. “Especially in medical technology, development projects require flexible, fast, and simultaneously quality-assured manufacturing partners. 1zu1scale combines rapid tooling, cleanroom manufacturing, and ISO-13485-compliant processes very professionally,” reports Activoris Managing Director Axel Fischer. Just six months after the first meeting in December 2025, Activoris tested the fully assembled housing in small series.

Complex interplay with a long tolerance chain

On the 15-centimeter-long inhaler, three elements – mesh cartridge, reservoir component with integrated mouthpiece, and the base unit with technology and battery – fit together into a compact device. The patient triggers aerosol generation with their inhalation via the approximately four-centimeter-long exchange cartridge. “That is the sensitive point. Here, every hundredth of a millimeter counts,” emphasizes Activoris product developer Tobias Kolb.

The function is reflected in the complex design of the assembly: it consists of two 2-component parts, contains pressure sensor and electrical connections, as well as bendable flaps for snapping into place. The interplay requires precision and stability. 1zu1scale relies on aluminum tools for manufacturing. This allows details to be easily and cost-effectively fine-tuned during the testing phase.

Scaling at the push of a button

With the series-ready system, Activoris now begins validation. In the context of clinical studies, demand could rise to up to 100,000 units per year. 1zu1scale can increase capacity at any time. Its setup allows the seamless switch to steel tools and manufacturing in the ISO Class 8 cleanroom. “Activoris approached us with the final 3D-printed prototype. When transitioning to series production, we were able to leverage all our strengths and present a fast and long-term reliable solution,” says Thomas Kohler, CEO of 1zu1scale.