Customer Profile
Industry: Medical device prototyping (individual maker) | Location: Austin, Texas, USA | Order: 6 PEEK parts, 3 iterations, 1-month engagement
The Challenge
“I called 12 shops. 8 said ‘we don’t do PEEK.’ 3 quoted $800+ per part with 4-week lead time. One said ‘minimum order 50 units.’ I just needed 6 parts for a medical device prototype.”
An independent medical device innovator needed small PEEK (polyetheretherketone) components for a surgical instrument prototype. PEEK is notoriously difficult to machine — high melting point, abrasive to tooling, and prone to stress cracking if machined incorrectly. Most shops reject small PEEK orders due to setup cost and material risk.
How QDJ Helped
- Material Expertise: Pre-heated PEEK stock to 120°C before machining to reduce internal stress. Used diamond-coated tooling specifically for PEEK.
- Low MOQ: 6 parts accepted — no minimum order. QDJ runs small-batch prototyping as core business, not a favor.
- Design Feedback: Suggested increasing wall thickness on one thin-walled section from 0.8mm to 1.2mm after FEA analysis showed potential cracking risk during autoclave sterilization.
- Certificate of Conformance: Provided material cert, machining parameters, and surface finish report for FDA submission package.
Results
| Metric | Other Shops | QDJ |
|---|---|---|
| MOQ | 50+ units | 1 unit |
| Per-part cost (6pcs) | $800+ | $195 |
| Lead time | 4 weeks | 7 days |
| DFM feedback | None | Wall thickness improvement |
Client Verdict
“QDJ didn’t just say yes when everyone else said no — they actually understood PEEK. The wall thickness suggestion was spot-on. Our prototype passed FDA review with zero manufacturing questions.”