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D-Rev, the designer and manufacturer of a low-cost prosthetic knee joint that recently won Proto Labs’ Cool Idea award, is receiving injection-moulded parts from the company to fulfil its next round of testing.

The Cool Idea award was launched by Proto Labs in 2011 to give product designers the ability to bring their innovations to life by presenting up to $250,000 worth (approximately £162,000 worth) of prototyping and short-run production services to award recipients.

The Remotion knee joint allows above-the-knee amputees in developing countries to walk stably on uneven or unpaved terrain, helping them return to work and remain independent. It uses a polycentric mechanism, similar to anatomical knees, to provide greater stability.

As part of the Cool Idea award, 100 knee joints will be injection moulded and used in field testing to ensure performance as manufacturing transitions from CNC machining to injection-moulded parts.

Key benefits of product application

  • With the Cool Idea award, product manager Vinesh Narayan said D-Rev was able to test the new knee design with much less risk by only producing 100 injection-moulded knee joints.
  • According to Narayan, working with Proto Labs has accelerated the project without adding risk.

Proto Labs

Proto Labs delivers fully functional prototypes in production-intent materials to dramatically cut the cost and time normally associated with product development. This empowers designers and engineers with the means to rapidly develop, test, and get their products to market first in an ever-competitive global market place.

Proto Labs delivers fully functional prototypes in production-intent materials to dramatically cut the cost and time normally associated with product development. This empowers designers and engineers with the means to rapidly develop, test, and get their products to market first in an ever-competitive global market place.

Protomold delivers injection-moulded parts from moulds manufactured utilising state-of-the-art high-speed CNC machining technologies. Parts can be moulded using almost any engineering-grade resin and are ideal for prototyping, bridge tooling and low-volume production.

First Cut satisfies the need for functional prototypes much earlier in the development cycle for quantities of 1–10+. Because First Cut delivers prototypes in engineering-grade resins and aluminium they will have real material properties and improved surface finishes. In other words, they will be functional.

When you submit your 3D CAD model, Proto Labs’ powerful super-compute cluster creates an interactive quote giving pricing options and where appropriate, suggesting changes to improve manufacturability. You simply interact with your quote online, tailor options such as material and delivery to your requirements and with every change, the pricing information automatically updates. This built-in ‘what-if’ analysis enables last-minute project refinements to be accommodated at the click of a button.

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