Engineers In Action
What happens when a surgical device fails—and how engineering brings it back to life
A leading medical device company developed a surgical tool designed for use in operating rooms. During real-world procedures, however, the device revealed a critical issue: it would intermittently fail mid-surgery. While surgeons discovered a workaround to re-engage the tool and finish the operation, it was far from ideal.
Determined to resolve the problem, the device’s lead engineer went into the operating room to observe surgeons in action. By studying how and when the failure occurred—and why the workaround was effective—the root cause was identified: the power stage had been mis-designed and required a complete redesign.
From Prototype to Production: How Allstar Helped
The manufacturer turned to Allstar Magnetics, their magnetic solutions provider. Our team stepped in during the early development phase to help troubleshoot, prototype, and refine the redesign. Beyond solving the technical problem, we collaborated with the client to ensure the solution could be efficiently scaled into production.
By combining engineering expertise with practical manufacturing foresight, Allstar helped move the redesigned device from concept to reality—restoring reliability in the OR and protecting patient outcomes.
Advice from Our Engineers
Many of our medical device partners bring us in early in the design process, not just after problems arise, to fully benefit from our end-to-end engineering and manufacturing expertise. That’s because Allstar looks ahead—evaluating materials, manufacturability, and cost efficiency while prototypes are still being developed.
The payoff?
- Time savings by identifying potential design and production challenges upfront.
- Cost efficiency by aligning prototypes with scalable manufacturing processes.
- Peace of mind knowing a collaborative partner is invested in both design success and long-term production quality.
As one client told us: “We come to Allstar for the expertise, but we stay for the partnership.”
Ready to troubleshoot an issue or launch your next device? Contact Allstar Magnetics today to discuss how we can support your project at every stage—from prototype to production.








