CMF Casting Industry Awards “Component of the Year”
Component
Sylatech Cast Prosthetic Multi-Part Cast Thumb for use by Children
Application
Medical prosthetics
Metal
A356 (AlSi9MgMn alloy)
Process
Lost-wax, using 3D wax printing and plaster block investment casting
Casting Weight
Comprises 7 parts with combined weight of 23.7g
Project Information
Brand new design for multi-part thumb designed by renowned prosthetic hand designer Ted Varley, for use by children who have lost a hand due to injury, congenital conditions, or for other medical reasons, enhancing their quality of life and enabling them to regain confidence and their independence.
Challenges and Achievements
- High level of detail and as-cast surface finish required requiring no machining.
- Minimisation of casting weight and maximising internal space for electronics.
- Wall thickness down to 2mm for some cast elements and 1mm diameter cast-in holes.
- Design flexibility enabled through use of 3D wax printing
- Samples provided to client with a lead time of just 3 weeks including heat treatment.
- Significant cost savings achieved compared with alternative production processes.
- New design has attracted NHS funding to enable further versions aimed at children.
- The company is now looking at further even smaller, lighter designs and are delighted that their castings are changing lives for the better.
