Rapid Tooling: From 3D Printing to Mass Production in 6 Months

Rapid Tooling for Medical Device Injection Molding From 3D printing to mass-production injection molding in six months

2026-10-21 Source: Press release Matthias Gutbrod 1 min Reading Time

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For Activoris’ Elaera inhaler platform, 1zu1 Scale manufactures three assemblies consisting of a total of eight injection-molded components. Using aluminum molds, the company successfully transitioned from a 3D-printed prototype to a certified small-batch production run in just six months.

1zu1 Scale produces three assemblies via injection molding for Activoris' Elaera mesh inhaler platform.(Bild: Darko Todorovic) — 1zu1 Scale produces three assemblies via injection molding for Activoris' Elaera mesh inhaler platform.
(Bild: Darko Todorovic)

The 15-cm-long mesh inhaler requires complex interaction among three assemblies: the replaceable cartridge with an aerosol generator, the reservoir component (including the mouthpiece), and the base unit housing the electronics and battery. The entire system comprises eight injection-molded components, including two two-component designs with integrated interfaces for pressure sensors and flexible latches. Six months after the project began in December 2025, the manufacturing specialist 1zu1 Scale delivered the first production-ready assemblies for testing.

Aluminum tools ensure tight tolerances

The mechanical interface of the replaceable cartridge, which measures about four centimeters, places high demands on the tool’s dimensional accuracy. “That’s the critical point,” emphasizes Tobias Kolb, product developer at Activoris. “Every hundredth of a millimeter counts here,” adds Kolb, referring to the tolerance chain involved in the automatic aerosol release triggered by inhalation.

1zu1 Scale manufactures high-quality mass-produced components using injection molding for medical technology specialist Activoris.(Bild: Darko Todorovic) — 1zu1 Scale manufactures high-quality mass-produced components using injection molding for medical technology specialist Activoris.
(Bild: Darko Todorovic)

To implement geometric adjustments cost-effectively during the testing phase, the manufacturer specifically uses aluminum molds in rapid tooling. “Activoris approached us with the final 3D-printed prototype,” reports Thomas Kohler, CEO of 1zu1 Scale. “When transitioning to series production, we were able to present a fast and long-term reliable solution,” Kohler emphasizes.

Seamless scalability up to the ISO Class 8 cleanroom series

Following the successful assembly of the small production run, validation of the medical device will begin. As part of the upcoming clinical trials, demand is expected to increase to up to 100,000 units per year.

Tobias Kolb and Axel Fischer of Activoris with the Elaera Inhaler.(Bild: HTAI/Bartels + Drescher) — Tobias Kolb and Axel Fischer of Activoris with the Elaera Inhaler.
(Bild: HTAI/Bartels + Drescher)

“In medical technology in particular, development projects require manufacturing partners that are flexible, fast, and at the same time ensure quality,” explains Axel Fischer, CEO of Activoris. “1zu1 Scale combines rapid tooling, cleanroom manufacturing, and ISO 13485-compliant processes in a highly professional manner,” Fischer continues. The setup allows for the transition from aluminum to steel tools as well as cleanroom manufacturing in accordance with ISO Class 8. (mg)

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