Industrial CT scanning: Turning complexity into confidence in medical device manufacturing

Aptyx is a global design and manufacturing partner that engineers smart solutions to solve complex, mission-critical challenges in medical device manufacturing. From engineering and design to precision molding (injection, dip, and blow), extrusion, specialized coatings, and full-scale assembly, Aptyx offers a range of capabilities to help some of the world’s leading medical manufacturers bring innovation to life.

As Aptyx’s customers pushed the boundaries of medical innovation, Aptyx recognized that its metrology capabilities would also need to evolve to keep pace.

“We had many programs coming in that carried a tremendous metrology load. I saw this tsunami wave coming at us, and I knew I had to look at other technology,” said Ray Scherer, Global Engineering Manager.

Adding to the challenge, many of the parts Aptyx works with are plastic and quite complex, making them susceptible to shrink variation and deformation. Current inspection methods were time-consuming and measured only a subset of features or small areas of the part. As a result, it was difficult to understand the part’s overall shape fully. Without a complete picture, making confident mold adjustments became challenging, often leading to lengthy investigations and, in some cases, costly rework.

“When you’re measuring only certain portions of a part, you don't get the entire picture. When you're developing a mold and trying to get it to work as it should, relying on limited samples and measurements can lead you to make the wrong decision. The mold may be doing something completely different than you think it is— and speed runs in the sample size. The longer inspection takes, the fewer samples you can get through in a timely manner to make a decision,” said Senior Quality Manager Lew Chappel.

Customer expectations for faster speed-to-market exacerbated the challenges.

“The timelines are getting shorter and shorter. Customers are putting more pressure on us to deliver. Parts are becoming more complicated. It’s becoming more difficult to measure some of the things that are being asked of us,” said Jarrod Aydelott, Director of Tooling and Molding.

One project brought these challenges to a breaking point. It involved a critical performance piece that had an interface interaction with a lever. The snap features for the lever were extremely small. Due to the features' size and location, they could not be measured using current methods.

The ZEISS METROTOM CT scanner introduced improvements that went beyond mold development. Simplifying processes and reducing reliance on complex fixtures increased overall workforce efficiency. “Previously, fixturing concerns added delays,” said Chappel. “Now, we load multiple parts onto foam fixtures simultaneously and scan them, gathering comprehensive data for geometric comparisons upfront.”

This approach allows multiple team members, even those without metrology expertise, to manage scanning, increasing productivity. “The simplified process lets anyone load multiple parts and start scanning. Then they are freed up to focus on other work in the meantime,” said Chappel.

Working with complete digital twins of parts also fosters cross-department collaboration.

“Jarrod can get with our tech, Ryan, and say, ‘Can we look at it this way? Where’s that and this?’ With a 3D model on the screen, you can pick any point you want and figure out what's going on— and having more data up front really helps to drive the decisions made later,” said Chappel.

ZEISS INSPECT X-Ray software makes data easier for teams across the organization to interpret and empowers them to act on it. The software’s intuitive interface allows team members to retrieve and review scans without needing specialized training. “I get all the information myself, where before I would be reliant on somebody else who could potentially be too bottlenecked to give me information for a week. Having user-friendly software and the ability to share the data files anywhere is a huge benefit,” said Aydelott.

Aptyx now uses CT scan data to help train quality engineers and technicians, building a more adaptive workforce capable of identifying potential issues even in unfamiliar manufacturing processes. “Now they can see exactly why parts distort, move, or develop voids during molding. They gain a better understanding of the root causes, and that’s huge in training, learning, and advancing people,” said Scherer.

This knowledge enables team members to proactively assess potential issues, ensuring smoother project launches. “It helps people to think proactively about possible issues that could arise on the next project. They think, 'This part deformed at the end, and now I understand why. And maybe this one could be like that, too.' Now we have more people thinking through the root cause of potential problems, and it's not just relying on a couple of people with a lot of experience to answer all the questions for everyone,” says Aydelott.

CT technology also helped break down organizational silos, forming a global inspection group that now serves multiple Aptyx locations. “Before, each location worked individually, but now one can support another by programming the scanner and doing diagnostic work remotely,” explained Scherer.

This shared access to detailed, visual data also aids communication with designers, especially those early in their careers. “We can visually demonstrate what’s working and what isn’t. It’s an effective way to teach and build confidence across teams,” said Aydelott.