By Sean Fenske, Editor-in-Chief

Automation is gaining substantial interest from medical device manufacturers across many sectors. With so much uncertainty in distant supply chains, companies are seeking to bring manufacturing closer to the point of sale or area of focus. As such, they may face challenges in doing so, including the lack of sufficient labor for the tasks they need to have accomplished. Automation can help address this concern.

In addition, automation can also help with the scale-up of greater production volumes. While improving accuracy and efficiency, companies can exponentially increase output to meet the industry’s needs. This is true with personalized medical device solutions as well, including orthopedic implants customized for each patient. While traditionally a more labor-intensive process, automated systems can handle repetitive tasks, enabling greater numbers to be produced while still personalized for each patient.

To help further explain how automation is impacting the production of personalized orthopedic devices and implant, Nora Toure, the director of Medical Sales North America for Materialise, responded to several questions in the following Q&A. She tackles a number of topics many orthopedic device makers ask about regarding personalized healthcare, orthopedics, and automation.

Sean Fenske: What factors are driving the medical device manufacturing (and healthcare) industry to explore automation more?

Nora Toure: The healthcare and medical device industries are under constant pressure to improve patient outcomes, reduce errors, and optimize efficiency—all while managing costs. Automation addresses these challenges by streamlining workflows, enhancing precision, and reducing human error. Additionally, the increasing demand for personalized medicine, regulatory compliance, and the need to accelerate time-to-market for innovative devices are key factors driving automation forward. As the complexity of healthcare delivery grows, automation offers scalable solutions that allow teams to focus on high-value tasks while technology handles repetitive or time-intensive processes.

Fenske: How are digital solutions such as artificial intelligence (AI) and scripting contributing to the effectiveness of automation?

Toure: AI and scripting are game changers in automation: AI enables predictive analytics, pattern recognition, and decision-making processes that were previously impossible. For instance, AI-enabled segmentation algorithms can process complex medical imaging data faster and with greater accuracy than manual methods. Scripting adds an additional layer of flexibility, allowing engineers and developers to programmatically interact with software, customize workflows, and implement new features specific to their needs. Together, these tools help reduce inefficiencies, improve precision, and drive innovation across design, development, and manufacturing processes.

Fenske: What are the primary benefits realized from automation in medical device development and manufacturing?

Toure: Automation brings multiple benefits, including increased efficiency, reduced costs, and enhanced consistency in quality. By automating repetitive tasks like segmentation or analysis of medical imaging, companies free up valuable human resources for strategic work. Automation, when kept in check by humans, also reduces the risk of human error, leading to safer and more reliable devices. Furthermore, advanced AI and digital solutions support scalability, allowing workflows to transition smoothly from early-stage prototyping to full-scale commercialization.

Fenske: How is automation being used in the movement toward patient-specific healthcare and personalized orthopedic devices?

Toure: Patient-specific devices require precision and customization, which makes automation a perfect fit. Software like Materialise Mimics leverages AI to convert CT, MRI, or ultrasound data into 3D models, enabling highly accurate anatomical visualization. Over time, repetitive processes such as image segmentation can be automated using scripting tools or AI algorithms, significantly reducing the time required for these tasks. Additionally, platforms like Mimics Flow facilitate end-to-end workflows, from early R&D to clinical trials and commercialization. These solutions not only improve the efficiency of producing personalized devices but also enhance their effectiveness through advanced visualization and statistical shape modeling.

Fenske: What are the most significant challenges for a company seeking to leverage automation for the development and manufacture of patient-specific orthopedic devices? Where is there room for improvement?

Toure: One major challenge is integrating automation into existing workflows while ensuring compliance with stringent regulatory requirements. Companies often struggle to strike the right balance between automation and human oversight, particularly in tasks that involve clinical decision-making. Room for improvement lies in creating more intuitive automation tools that require less specialized training and can be seamlessly adopted across multidisciplinary teams. Enhancing interoperability between different software platforms and medical imaging modalities is another area where innovation could unlock significant value.

Fenske: What important factors do companies not always consider or overlook when considering automation?

Toure: Companies sometimes underestimate the importance of change management and staff training when adopting automation. Even the most advanced solutions require buy-in from end-users and proper onboarding to maximize their effectiveness. Another often-overlooked factor is the scalability of automation tools—what works for prototyping may not be as effective when scaled for commercialization. Additionally, companies must carefully evaluate data privacy and security considerations, particularly when dealing with sensitive patient information in AI workflows.

Fenske: Do you have any additional comments you’d like to share based on any of the topics we discussed or something you’d like to tell orthopedic device manufacturers?

Toure: Automation is not just a tool—it’s a catalyst for innovation in medtech. For orthopedic device manufacturers, the key is to approach automation strategically, keeping patient outcomes at the center of every decision. Leveraging AI, scripting, and advanced visualization tools can help companies develop safer, more effective devices while also scaling their operations. By focusing on flexibility, compliance, and long-term scalability, manufacturers can position themselves as leaders in the movement toward personalized, patient-specific healthcare.

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