The Estes Medical Design and Manufacturing division is an FDA-registered, ISO 13485:2016 certified design and medical manufacturing facility that has been serving the medical industry for more than 30 years.
From conceptual design to prototyping and manufacturing a final product, Estes is your one-stop manufacturer for surgical trays, X-ray shields and screens, sterilization equipment, exam room tables, medical refrigeration and cabinet components/panels, ventilator components, fluid management devices, hospital bed components, operating room equipment, custom latches, wire handles, and other medical devices.
INNOVATIVE | AUTOMATED | COST-EFFECTIVE
The Estes Difference
Innovation • Engineering Expertise • Highly-Specialized Automation
Estes is different from many other medical device manufacturers, which is why so many leading medical technology companies choose to work with us. The Estes difference includes:
Creative, Innovative Thinking – The Estes prototyping team is a core group of engineers and designers who challenge modern methods and are committed to solving problems. Our team is focused on reducing lead times and finding cost-effective solutions for our customers.
State-of-the-Art Technology – Estes is committed to utilizing lean processes and the latest automated fabrication systems to ensure that our customers get precise, high-quality, best-in-class products.
Ability to Scale – Estes employs a staff of more than 90 associates, has 85,000 square feet of manufacturing space, and features a high level of capacity-multiplying automation to provide even the largest companies with on-time fulfillment services.
Trustworthy Team – For over four decades, Estes has been committed to hiring people of high character who are focused on delivering the highest level of service to medical OEMs.
Medical Device Production Capabilities
Estes can design, prototype, and manufacture a wide range of sheet metal medical devices and components using materials such as stainless steel and aluminum, along with silicone inserts where required. Through established finishing partnerships, Estes can also support services including powder coating, anodizing, passivation, electropolishing, screen printing, and other specialized finishing processes. Our sheet metal fabrication capabilities include surgical instrument trays, X-ray shields and screens, sterilization cases and components, medical cabinets, and more.
OUR PROCESS
01 | Design Input
We believe the best results come from collaboration. It begins with asking the right questions and listening closely. Once we understand your product requirements, performance needs, and application, we work with you to develop practical solutions for your medical device and medical equipment design challenges.
02 | Conceptual Design
With a shared vision in place, we work closely with your engineering team to develop concepts and rough layouts for the product or component. This allows us to evaluate fit, function, manufacturability, and key design considerations before investing time in the details.
03 | Detailed Design
Our design team brings the concept together with a focus on performance, manufacturability, durability, and efficiency. Where possible, we simplify designs and reduce component count to help lower costs, shorten assembly time, minimize potential defects, and support the requirements of the final application.
04 | Prototype
This is where the concept becomes tangible. We produce a fit-and-function prototype so you can evaluate the product, verify critical features, and conduct any required performance or validation testing. If issues arise, we can address them before moving into production.
05 | Manufacture
With Estes, you gain a manufacturing partner that has been involved from the start. Our medical sheet metal fabrication and contract manufacturing capabilities support a wide range of medical devices, equipment, enclosures, and components. Using automated fabrication technologies, we help OEMs achieve the quality, consistency, repeatability, and production efficiency their applications require.
Let Estes take your medical product design to the next level.
Case Studies
CASE STUDY #1
CUSTOMER CHALLENGE
An industry leader in medical devices & orthopedic care was developing an orthopedic case and tray delivery system that would be sold globally and would need to withstand the harsher cleaning processes in Europe that were adversely affecting plastic and anodized aluminum products.
ESTES SOLUTION
Our designers developed an innovative custom system that was made completely of stainless steel instead of plastic or anodized aluminum.
RESULT
The stainless steel tray was able to endure the harsher cleaning processes and offered improved sterilization.
CASE STUDY #2
CUSTOMER CHALLENGE
In order to reduce production costs, a leading manufacturer of light boxes for medical imaging professionals needed to redesign a steel pan. The original design was a three-piece, spot-welded assembly that cost $29.65.
ESTES SOLUTION
To increase the manufacturing efficiency, the Estes team moved the production from the press brake equipment to their Salvagnini forming cell. The three components were consolidated into one complex part that had twelve bends.
RESULT
The redesign eliminated several secondary operations and reduced the overall production cost to $18.82, a 37% savings.
Certifications
Estes is ISO 9001:2015 and ISO 13485:2016 certified.
Frequently Asked Questions (FAQ):
Q. What is design for manufacturability?
Answer
Design for manufacturability (DFM) is the process of evaluating a product design to identify opportunities to make the product or part easier, more efficient and more cost-effective to manufacture. Estes engineers work with customers to identify potential manufacturing challenges early and recommend design changes that can simplify fabrication and assembly.
Q. Can Estes help if my medical product is still in the concept stage?
Answer
Estes can engage at any stage of product development, from an early concept or sketch to detailed drawings and models. Our engineers and designers collaborate with your team to develop concepts, refine designs and create prototypes that can be evaluated before moving into production.
Q. What types of medical products can Estes design and manufacture?
Answer
Estes designs and manufactures a wide range of medical products and components, including surgical instrument trays, sterilization cases and equipment, X-ray shields and screens, medical cabinets, exam room tables, hospital bed components, ventilator components, fluid management devices and operating room equipment.
Q. What quality certifications does Estes have for medical manufacturing?
Answer
Estes is ISO 13485:2016 certified for medical device quality management and ISO 9001:2015 certified. Estes is also an FDA-registered facility, supporting the quality and regulatory requirements associated with medical product manufacturing.
Q. What makes Estes a good partner for medical product development?
Answer
Estes brings design, engineering and manufacturing expertise together to help medical OEMs address product and manufacturing considerations early in the development process. From initial design and prototyping through production, our team works collaboratively with customers to develop practical, manufacturable solutions.