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Medical Additive Manufacturing

At Smithstown Additive, we deliver cutting-edge additive manufacturing solutions tailored to the medical devices and orthopaedic implants industries.

We specialise in the design and development of medical components featuring advanced geometries that are lighter, stronger, and more durable, while being faster to produce than traditional manufacturing methods.

Our state-of-the-art additive manufacturing facility streamlines the entire process—from design assessment and validation to post-production finishing—all under one roof, ensuring efficiency and high-quality results and reduced risks at every stage.

 

Why Smithstown Light Engineering for Additive Manufacturing?

  • End-to-End Solutions: From initial design assessment and optimisation to prototyping, production, and post-processing, we manage the entire additive manufacturing lifecycle. This streamlined process ensures seamless project execution and consistently high-quality results.
  • Cutting-Edge Technology: Our facility is equipped with the latest 3D printing technologies, including Trumpf TruPrint for metal and Formlabs for polymer printing. We also use advanced simulation, optimization, and quality control software to ensure precision at every stage.
  • Industry-Leading Expertise: With years of experience in precision engineering, our team of experts works closely with you to deliver customised solutions. We’re committed to meeting the highest industry standards and helping you achieve your project goals.
  • Collaborative Approach: We believe in working alongside our clients to ensure each step aligns with your specific product requirements. We offer flexibility, including the ability to validate designs before production, ensuring optimal outcomes that meet your exact needs.

 

Find out how we bring your ideas to life and open up new possibilities for medical devices and orthopaedic implants.

 

Other Solutions

  • Precision Engineering
  • Medical Device Contract Manufacturing

 

Our End-to-End Additive Manufacturing Solutions

Smithstown Additive offers a full-service additive manufacturing solution designed to meet your needs at every step of the process:

Design Assessment and Optimisation

We work with you to assess your product design and optimise it for performance and manufacturability using tools like Siemens NX AM and Topology Optimisation, ensuring it’s ready for the additive process.


Prototyping

Prototyping allows us to create a physical model of your design for validation and refinement before full-scale production, reducing risks and ensuring the final product meets your requirements.


3D Printing

We employ advanced metal and polymer 3D printing technologies, including the Trumpf TruPrint 2000 for metal parts and the Formlabs Form 3BL for medical device prototypes and end-use parts. These printers offer flexibility in materials and design complexity.


Quality Assurance

Each part undergoes thorough quality control using Zeiss O-Inspect and GOM Atos technologies to ensure precise, reliable results.


Post-Processing

Our extensive post-processing capabilities include laser cutting, 5-axis machining, surface grinding, and EDM techniques, ensuring every part achieves the highest level of finish and functionality


 

Key Equipment & Technologies

We use industry-leading equipment to deliver top-quality additive manufacturing services:

 

Metal Additive Manufacturing

 

Trumpf TruPrint 2000

The Trumpf TruPrint 2000 is a high-precision metal 3D printer with a build volume of Ø200 mm x 200 mm. It delivers strong, accurate metal parts using advanced powder bed monitoring and inert gas shielding. Ideal for complex metal components.

  • Build volume (cylinder): Ø200 mm x 200 mm Height
  • Maximum laser power: 300 W
  • Beam diameter: 55 μm
  • Layer thickness: 20 -100 μm
  • Shielding gas: Nitrogen, argon
  • Inert and closed powder cycle
  • Powder preparation station
  • Supply of powder in shielded gas
  • Powder Bed Monitoring – Monitoring of the powder layer by layer
Polymer Additive Manufacturing

 

Formlabs Form 3B

The Form 3B is a versatile 3D printer designed for life-sized prototypes and end-use medical device parts. With a large build volume (33.5 x 20 x 30 cm) and FDA-cleared workflows, it’s ideal for producing high-quality medical components.

  • Build volume 33.5 × 20 × 30 cm
  • Life-size 3D prints
  • On-demand printing
  • Validated in FDA-cleared workflows
  • Ideal for medical device prototypes, jigs, fixtures, assemblies, and end-use parts
AM Software Capabilities

 

Siemens NX AM Fixed-Plane Advanced

This is a manufacturing authoring application for fixed plane AM. It provides build tray setup, basic and advanced support geometry types. It provides the build processor framework, which supports Trumpf build processors. It also provides 3MF and STL file-based export of the build tray.

 

Siemens NX Lattice Structures

The Siemens NX Lattice Structures Design add-on provides the ability to create various types of lattice structures typically used in additive manufacturing to optimise weight and material while maintaining or even improving structural integrity.

 

Simcenter 3D Additive Manufacturing

Simcenter 3D Additive Manufacturing simulates the additive manufacturing process for Selective Laser Melting (SLM). The setup from a part in the built tray including support structures is used as a basis. The user selects the parts to simulate, defines printing process parameters (material, number of parts, layer slicing, laser parameters, etc) and runs the simulation. The result is the temperature distribution and distortion of the part. A compensated geometry can be generated and be re-simulated.

 

Topology Optimisation

Topology Optimisation provides the ability to create geometrically optimised structures that fit within a specified design space while meeting the various performance, material and manufacturing requirements.

Inspection Equipment

 

Zeiss O-Inspect

The Zeiss O-Inspect is a high-precision 3D measurement system, combining tactile and optical sensors for accurate, detailed inspections of complex parts, ensuring precise dimensional measurements and reliable results.

  • Measuring Volume 500 x 400 x 300mm³
  • Length measurement error: in 2D 1,7µm+L/250 µm in 3D 1,9µm+L/250 µm
  • Zeiss Vast XXT provides quick and precise 3D tactile measurements
  • Zeiss zoom lens provides a large distortion free field of view for measuring results with excellent accuracy and significant reduction in measuring time

 

GOM Atos Q

The GOM Atos Q is a high-precision 3D scanner that captures detailed shape and dimension data of complex parts. It offers fast, accurate measurements with up to 8 million points per scan, ensuring reliable quality control and inspection.

  • Measuring Volume 270 x 200mm²
  • Points per Scan 2 x 8 Million
  • Rotating Table 350mm
  • Delivers fully traceable measurement results
  • ATOSQ captures quality information quickly and with a high degree of detail
  • GOM inspection software for shape and dimension analysis
Heat Treatment

 

TAV H4S Vacuum Furnace

The TAV H4S Vacuum Furnace is designed for high-performance heat treatment applications, offering precise control over temperature, vacuum, and cooling processes.

Dimensions: 400 width x 400 height x 600 length

Loading Flexibility: This furnace type enables quick and easy loading of different volumes giving the flexibility for various production or R&D applications. The stated operating vacuum is 10-4/10-5 mbar.

Convection & Vacuum Heating: The forced gas convection in the first phase of the thermal cycle improves uniformity at low temperatures facilitating irradiance and improving the heating speed in the middle of massive loads. Max operating temp = 1250 deg C.

Multi-Cooling Directions: Gas quenching (pressure 9.5bar max) is a critical part of the heat treating process in order to ensure metallurgical and mechanical transformation without exceeding the specified distortional tolerances. In hinged door furnaces operator can easily drive the gas flow where required.

Post-Processing

 

Our 80,000 sq-ft facility is equipped with advanced machinery for post-processing additive manufactured parts, allowing us to offer you the latest in advanced manufacturing methods for post processing of additive manufactured parts. Some of our capabilities include:

  • Laser Cutting
  • 5 Axis Machine Centres
  • 3 Axis Machine Centres
  • Mill / Turning
  • Surface Grinding
  • OD / ID Grinding
  • Jig Grinding
  • Spark EDM
  • Wire EDM
  • Laser mark and Pad Printing Equipment
  • Surface Finishing
  • Passivation and Cleaning

 

Best-in-Class 3D Printing Materials

3D Printing materials at Smithstown
Choice of 3D Printing materials at Smithstown Additive

 

Leveraging Carbon DLS technology, we offer premium 3D printing materials for producing functional, real-world medical device parts. These materials provide excellent mechanical properties, high resolution, and exceptional surface quality for isotropic parts.

We offer a wide selection of both rigid and flexible materials, including polyurethanes, silicones, cyanate esters, and urethane methacrylate.

Whether you need high-performance materials with strength, stiffness, and temperature resistance, or softer, biocompatible, tear-resistant options, we have the perfect solution for your medical device needs.

 

 

 


 

Industry Certifications & Recognitions

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Verified Registration 2021 

 


Let’s Talk

Reach out to us today to discuss your project and explore how our additive manufacturing expertise can benefit your business.

Call us: +353 (0) 61 362 111

Email us: info@sle.ie

 

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Our Locations


Shannon Site 1
Smithstown Light Engineering, Bay H1A Smithstown Industrial Estate, Shannon, County Clare, V14 W594 Ireland.
Get Directions 353 (0)61 362111 info[@]sle.ie
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Shannon Site 2
Smithstown Light Engineering, East Park, Shannon, County Clare, V14 NW92 Ireland.
Get Directions 353 (0)61 362111 info[@]sle.ie
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Poland Site
Smithstown Polska, Kapitałowa 3, 35-213 Rzeszów, Poland.
Get Directions +48 17 881 11 30 info[@]smithstown.pl
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Smithstown Light Engineering - Site I Bay H1A Smithstown Industrial Estate, Shannon, County Clare, V14 W594, Ireland Smithstown Light Engineering - Site II Bay K, East Park, Smithstown, Shannon, Co. Clare, V14 NW92, Ireland
+353 (0) 61 362 111
info@sle.ie
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