Estes brings medical design innovation and fabricating automation to the medical industry it’s been serving for over 30 years.

We work with top medical manufacturers to deliver precision fabricated sheet metal products that cost-effectively combine form with function. We are your innovative design partner, not just another vendor.

 

Contact Estes Medical Design to learn how our innovative approach will help you deliver better quality – faster with greater cost efficiency.

Medical tray design
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INNOVATIVE APPROACH   |   FORM & FUNCTION

Let's Create Something Together

Simplified Bill of Materials • Improved Sterilization • Stylish Signature looks

Estes is different than 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 – Estes has assembled a core group of engineers that 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 the latest equipment and lean processes to ensure that our customers get precise, high-quality, best-in-class products.

Ability to Scale – Estes employs a staff of more than 110 associates, has 65,000 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.

PROCESS

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01 | Design Input

We believe the best results come from collaboration. It all begins with asking the right questions and then listening closely. Once we understand exactly what you need out of a case or tray, we provide thoughtful solutions to solve your medical product design challenges.

concept

02 | Conceptual Design

With a shared vision in place, we work closely with you engineering team to design concepts and create rough layouts of the product being produced. This allows us to collectively see the instrument placement and planned functionality before investing time in the details.

detailed design

03 | Detailed Design

Our design team starts to pull it all together, ensuring each instrument will be secure during the rigors of use. Our goal here is to use as few components as possible in our trays, which helps reduce cost, assembly time, potential assembly defects, and helps maximize sterilizability.

prototype

04 | Prototype

This is where the fun begins. We produce a fit and function prototype, allowing you to touch and test the product for instrument fit and to even perform sterilization validation testing. If any issues arise, we resolve them quickly before going into production.

Let us take your medical product design to the next level.

Case Studies

Case Study #1

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.

CLIENT NEED

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.

SOLUTION

The redesign eliminated several secondary operations and reduced the overall production cost to $18.82, a 37% savings.

RESULT

Case Study #2

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 hold up to the harsher cleaning processes in Europe that were adversely affecting plastic and anodized aluminum products.

CLIENT NEED

Our designers developed an innovative custom system that was made completely of stainless steel instead of plastic or anodized aluminum.

SOLUTION

The stainless steel tray was able to endure the harsher cleaning processes and offered improved sterilization.

RESULT

Case Study #3

A cardiologist and highly respected doctor realized there was a problem when a surgeon was working in a cath lab; the lead vest that must be worn is extremely heavy and wears on the surgeon, expending energy and making surgery much more difficult. The client wanted to created an invention that would take the weight of the vest off the surgeon, while also allowing for the mobility necessary for the surgeon to be successful.

CLIENT NEED

Our prototype and product development team worked together to design and develop a completely custom system that used a cable and zero-gravity suspension tool to remove the weight of the lead vest and also allow surgeons the flexibility to move as needed.

SOLUTION

The newly developed product has been successfully used in several surgeries and doctors have noticed the difference the zero-gravity suspension tool has made in making their surgeries much easier.

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RESULT

Certifications

Estes is ISO 9001:2015 and ISO 13485:2016 certified.