From DICOM to Device: What Happens After You Send Us the CT

Every patient-specific device begins as a stack of DICOM images. Between the moment radiology exports the study and the moment a sterilised implant arrives in theatre, the data passes through five controlled stages — each documented under our ISO 13485:2016 quality system. Knowing the pipeline helps surgical teams understand why scan quality caps what we can build.

Stage 1 — Receiving and validating the CT

We accept DICOM studies via the case form, WhatsApp or a cloud transfer link. The study is validated automatically: slice thickness, kernel, coverage and completeness are checked against the requirements for the requested device.

• Slice thickness: ≤ 1.5 mm (ideally 0.6–1.0 mm)
• Kernel: bone / sharp reconstruction
• Coverage: full region of interest plus healthy margins
• Format: standard DICOM, complete series

Stage 2 — Segmentation and 3D reconstruction

A biomedical engineer segments the anatomy by bone-density thresholding and region growing, producing a watertight 3D model. For defect cases the contralateral side is mirrored across the midline to define the anatomically ideal target shape that both our engineers and the surgeon review.

Stage 3 — Design and the surgeon's approval gate

The implant is designed on the segmented model: wall thickness to spec, perforation patterns, and fixation tabs on flat accessible bone. You receive a 3D PDF and STL preview for review. Nothing is manufactured until you approve in writing — two revision rounds are included in every quotation.

Stage 4 — Manufacture, verification and delivery

Approved designs are printed in medical-grade titanium by laser powder-bed fusion, heat-treated, finished and dimensionally verified. Validated scan to delivery typically runs 7–10 working days standard, or 3–5 on the urgent pathway. Submit the CT through the case form and you'll have a firm quotation within one working day.