How RpProto delivered a complete laser hair removal device prototype run for a European medical aesthetics company — on time, across four materials and six manufacturing processes.
50
Complete Assemblies
20
Days to Delivery
4
Materials Used
6
Manufacturing Processes
An International Deadline. A Complex Device.
A well-established European medical aesthetics company was preparing to launch its next-generation laser hair removal device at an upcoming international trade show. With a tight deadline and high expectations for presentation quality, the client required 50 complete functional prototypes delivered within 20 days — intended for exhibition display, market testing, and hands-on evaluation by potential buyers and distributors.
After evaluating multiple manufacturers, the client chose RpProto as their sole manufacturing partner, entrusting us with the full scope of production: from individual components across four material categories to final assembly and quality inspection.
Three Problems Most Manufacturers Can't Solve Together
This project stood out in terms of complexity, even by the demanding standards of medical device prototyping. The combination of constraints made it a project that required a truly integrated manufacturing operation.
Compressed Timeline
50 complete assemblies in 20 days left no margin for error. Every process had to run in parallel, and any delay in a single component would cascade across the entire delivery schedule.
Multi-Material Complexity
The device required ABS, cold-rolled steel, aluminum alloy 6061, and TPU — each demanding entirely different techniques, equipment, and specialist expertise under one roof.
Medical-Grade Standards
As trade show and market testing units, every prototype had to meet production-level quality in both structural integrity and surface finish — accurately representing the final commercial product.
Four Components. Six Processes. One Partner.
The device’s outer housing featured complex curvature and precise parting lines consistent with a premium medical aesthetic product. RpProto machined the housings from ABS billets using CNC milling, faithfully reproducing all surface geometries from the client’s design files.
Following machining, each housing underwent extensive hand sanding — progressing through multiple grits to eliminate tool marks and achieve a smooth, uniform surface. The finishing process moved through primer application, surface leveling, and multiple layers of topcoat, resulting in a flawless paint finish that met the visual standards expected at an international trade show.
The device interior housed a large number of aluminum functional components — heat dissipation structures, mounting brackets, and guide elements — with considerable variation in geometric complexity. Components with intricate geometries and deep cavities were machined on RpProto’s 5-axis CNC machining centers, allowing complex surfaces to be completed in a single setup. More straightforward structural parts were efficiently handled by 3-axis CNC equipment.
All aluminum components were then put through anodizing surface treatment, significantly enhancing corrosion and wear resistance while giving each part a clean, uniform appearance — a level of internal finish that reflects the quality expectations of a medical-grade product.
The structural backbone of the device was fabricated from cold-rolled steel sheet metal, processed through laser cutting, CNC bending, and welding to form the complete frame assembly. To support secure mounting of circuit boards and electronic modules, RpProto installed press-fit nuts (PEM nuts) at all designated locations — providing reliable threaded connections without risk of loosening.
The finished frames were treated with electrostatic powder coating, delivering a uniform, durable surface with excellent corrosion resistance, abrasion resistance, and electrical insulation — essential attributes for internal structural components in a medical device.
The device’s operational buttons and several soft functional components required materials that could accurately replicate the tactile feel, flexibility, and color fidelity of production TPU. Vacuum casting was the ideal process for this application.
RpProto produced high-precision silicone molds and cast polyurethane materials under vacuum conditions, faithfully reproducing the contours, textures, and mechanical properties of each part. For a quantity of 50 sets, vacuum casting offered a compelling combination of speed, cost efficiency, and part quality — without the lead time or expense of injection mold tooling.
Inspection First. Then Assembly.
With all components manufactured across their respective processes, every part entered RpProto’s quality inspection workflow before assembly. The inspection team verified dimensional accuracy against the client’s drawings and tolerance specifications, evaluated surface finish on all visible components, and flagged any parts requiring rework — ensuring only conforming parts proceeded to the assembly line.
RpProto’s assembly team then built up each unit in accordance with the client’s documentation, integrating housing, internal frame, aluminum components, buttons, TPU parts, and client-supplied electronic elements into complete, functional prototypes. Each finished unit underwent a final functional check and visual inspection before clearance for shipment.
All 50 laser hair removal device prototypes were completed and shipped on schedule within the 20-day window, arriving at the client’s facility in time for trade show preparation.
At a Glance
Delivery Quantity 50 complete assemblies
Lead Time 20 days
Outer Housing ABS · CNC Machining · Painting
Internal Frame Cold-Rolled Steel · Sheet Metal · Press-Fit Nuts · Powder Coating
Aluminum Components 6061 Aluminum · 3-Axis & 5-Axis CNC · Anodizing
Soft Components TPU · Vacuum Casting
Final Processes Quality Inspection · Full Assembly
One Partner. Every Process. On Time.
Delivering 50 complete medical device assemblies across four material categories and six manufacturing processes — all within 20 days — requires a fully integrated facility with the machines, expertise, and project management discipline to run multiple workflows simultaneously without compromising quality. That is exactly what RpProto is built for.
When your project demands speed, complexity, and precision all at once, RpProto has the capability to deliver.
