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Our client is a leading U.S.-based spinal implant company. They had an urgent need for a contract manufacturing partner to manufacture bone screws with an extremely complex design within a very short lead-time. The bone screws were needed for emergency scoliosis surgery for a six-year-old boy. The Pulse Technologies team was able to:
- Meet the challenging lead time and complex manufacturing specifications
- Help ensure emergency surgery success
This case study explains the innovative solutions and approach adopted by the Pulse team to successfully meet the surgery deadlines and, most importantly, improve the life of the young patient.
About the Client
Our client is a leading innovator in the medical device industry specializing in advanced solutions for spine surgery. They are headquartered in the U.S. but also have a global footprint with a presence in several countries. The client sells a portfolio of products used in minimally invasive spinal surgery and other cutting-edge surgical products. Their commitment to innovation and patient well-being distinguishes them as a key player in the industry.
Client Challenge
Our client faced an extremely time-sensitive challenge: an emergency patient surgery scheduled within a 30-day window. The patient was a six-year-old boy with severe scoliosis. The scoliosis was so advanced that one of his lungs was only half the normal size.
To address this complex case, a pioneering new technology was being used. This technology could grow with the spine, allowing for implantation at an earlier age. However, the intricate design and geometry of the bone screws necessary for this procedure posed a significant hurdle.
With the surgery deadline looming and lack of in-house capacity to manufacture these complex parts, our client reached out to us, seeking our expertise and manufacturing capabilities to ensure the timely production of these specialized components.
Pulse Solution
Understanding the gravity of the situation and the short lead-time to manufacture and deliver the complex bone screws, our team at Pulse got to work immediately.
- As a first step, we assembled an experienced, cross-functional team comprising manufacturing engineers with design for manufacturing (DFM) expertise, production planners and experienced machining operators.
- The team analyzed the product design in detail to understand the intricacies, tolerances required, and material and inspection requirements.
- After analyzing the design, the team mapped out the manufacturing process to identify any potential manufacturing issues in advance.
- Detailed production planning and scheduling helped us accommodate this urgent requirement without disrupting or delaying other commitments.
The Impact
- The Pulse team was able to manufacture and deliver the required parts successfully within the required lead-time.
- The parts delivered were used successfully to correct the debilitating medical condition and improve the patient’s quality of life.
- Our medical device customer and the patient’s family were appreciative of our efforts and responsiveness, going as far as to send us a detailed thank you note.
“At Pulse Technologies, we understand the critical role medical devices play in saving lives, especially in urgent situations. When our medical device customer approached us with the challenge of manufacturing complex bone screws for a six-year-old scoliosis patient, time was of the essence.
Our dedicated team worked tirelessly to manufacture and deliver the intricate design within an incredibly short timeframe. This experience reaffirms our commitment to manufacture the highest quality medical devices thus ensuring that every life we touch receives the best healthcare outcome possible.”
– Joe Rosato, President & CEO, Pulse Technologies
At Pulse Technologies, we offer:
- 30+ years of medical device manufacturing experience
- Industry-leading in-house metrology and testing capabilities
- 70,000-square-foot facility
- 100+ CNC machine tools.
- Data conveniently formatted for DHFs/DHRs and more
Want to learn more about our bone screw manufacturing capabilities? Contact us today.
