7 Ways Design Can Impact Orthopedic Manufacturing Costs

The costs of manufacturing orthopedic devices vary greatly depending on several factors. These include the complexity of the design, the materials used, etc.
 
Considering this it's important to understand that certain changes and modifications to design like the packaging of finished orthopedic products, can contribute to reducing the overall costs of producing expensive medical parts.
 
This article covers the seven ways design can increase or decrease orthopedic manufacturing costs, starting with the complexity of the design.

1. Design Complexity

Often, the design increases or decreases orthopedic manufacturing costs in part because of its complexity. The more complex the part, the more time it takes to make and test. This means that the larger the quantity of parts, the more time it can take to assemble and test each individually.
 
Combining these factors can result in an exponential increase in cost due to assembly time alone. As a result, part complexity has a direct correlation with price. The more complex the medical orthopedic part is, the higher its cost is.
 
This is a glaring concern in an industry where time is money. Many designers must always be mindful that every extra millimeter or surface area added increases the cost of production for parts without adding any value.

2. Packaging

Packaging is an important aspect of the manufacturing process. The protective layer secures the product and helps with shipping and handling costs. This can be expensive, considering the cost of designing and manufacturing packaging and the time spent on this part of the process.
 
The packaging design can be a big factor in the success or failure of a product. The right package will make customers want to buy it and help them understand what they are buying, giving clear details and directions.
 
Thus, packaging is one of the most important aspects of a finished product, and its economization in quantity or quality can help with shipping costs and sales.

3. Production Quantity

The more parts are designed, the more time and resources it will take to make each. The way around this is to design fewer parts. This is one of the best ways to reduce costs by reducing the number of parts manufactured individually.
 
In other words, thinking about how all of the part components fit together, that is, how they interact and fit into an assembled product or machine, helps to avoid having too many individual parts that need to be manufactured separately.
 
Thus, further contributing to reduced manufacturing costs and a simpler assembly process for orthopedic parts like CNC turning machines. When designing parts for an assembly, considering how each part fits together is also key to ensuring that the finished product works as intended.

4. Specialty Materials and Tight Tolerances

Specialty materials and tight tolerances are two factors that can increase the cost of manufacturing orthopedic implants. Specialty materials are more expensive because they require more time and effort to manufacture, especially for CNC turning.
 
This is because they have to be specially ordered, so an on-hand inventory might not be available when needed. Additionally, these high-quality materials come with tight tolerances that require greater precision from medical equipment.
 
Tight tolerances mean that equipment has to operate at a higher standard than normal to produce high-quality work consistently. This further increases the costs because extra time and money are spent on training employees to run their machines.

5. Inspection and Testing Requirements

The best way to reduce inspection and testing costs is to consider whether they are mandatory. When conducting inspections and tests, prioritizing the number of total tests and the importance of each one can make manufacturing much more efficient.
 
Also, the location of the test procedures can add to the costs of testing orthopedic parts. For example, if an inspection can be performed for a turning machine in the same place where a part is made (i.e., in the factory), that saves both time and resources.
 
In contrast, if an inspection has to be done after every step of production - for example, at different facilities worldwide - then this adds cost. This is because each step requires transportation between locations and no further progress can be achieved in the time spent waiting in between the steps.

6. Materials Used for Orthopedic Parts

The materials used in medical devices can greatly impact their upfront and long-term cost. The wrong material can lead to increased costs in both material costs and repairs later down the road.
 
Just a few examples of materials used during the manufacturing process include:
 

• Steel
• Stainless steel
• Aluminum
• Copper
• Brass
• Plastic
• Wood
• Ceramic
• Glass
• Carbon fiber
• Fiberglass

 
Many materials are more expensive than others, which is why the materials used to manufacture orthopedics can vary greatly.
 
For example, using low-grade parts can lead to costly replacements in the future because they tend not to last as long as higher-quality ones do. It's also important not to overspend on materials either during their procurement.

7. Nature of Parts Produced

Rigid design prevents changes as the development and manufacturing of orthopedic products continue. Throughout the process, rigid designs are more challenging to alter and update, which leads to unneeded cost increases.
 
This can be an issue as multiple manufacturing partners can lower costs by providing design for manufacturability support, but only if the design can be altered.
 
Modifying tolerances so that machines can produce the parts using standard tools is one of how the manufacturing process can be made both more economical and efficient.
 
If the design cannot accommodate the change, custom tools will almost certainly be required, raising costs substantially. Other ideas include modifying features to make them easier to examine, which is an important component.

Conclusion

Reducing costs is key for a business to grow and provide quality manufacturing. A good design can make the manufacturing process more efficient and less expensive. The best way to ensure a quality product is by considering the number of parts, materials used, etc. Keep these points in mind during new projects to avoid costly mistakes.
 

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Vincent Hua is the Marketing Manager at TSINFA. He is passionate about helping people understand high-end and complex manufacturing processes. Besides writing and contributing his insights, Vincent is very keen on technological innovation that helps build highly precise and stable CNC Machinery.