Greater dependability from design to production with 3D Printing.

Compared to conventional fabrication methods, industrial 3D printing or additive manufacturing (AM), provides greater dependability from conceptualized design to production. Using the same 3D printing process and material for both prototyping and manufacturing can positively impact the way products are developed and brought to market.

With production volumes fewer than 1,000 units annually and a relatively high unit cost ($20,000 and up), the complex electroencephalogram (EEG) devices by CGX demonstrate the advantages of additive manufacturing. For prototypes and manufacturing of the Quick-20r EEG headset, CGX turned to the 3D printing services at Avid Product Development.


CGX EEG HeadsetFor prototypes and production of the Quick-20r EEG headset, CGX utilized Avid’s HP Multi Jet Fusion (MJF) 3D printing services in PA 11. By using the same additive manufacturing method and material for each design iteration, CGX gained a fast and accurate way to understand the performance potential of the Quick-20r EEG headset.

After developing and testing multiple iterations, the final design of the CGX Quick-20r headset exemplifies the ability for part consolidation – one major benefit of design for additive manufacturing (DfAM). Combining 80 unique parts into 30, the headset features 19 “pods” that house EEG sensors and contact a person’s head to capture brain activity. Unlike traditional EEG headsets which are challenging to set up and uncomfortable to wear, these pods are adjustable and provide three degrees-of-freedom, a feature that would have otherwise require complex assembly. With 3D printing, the pods are preassembled digitally and manufactured.

Substantial cost savings was another key benefit for CGX to use Avid’s Multi Jet Fusion 3D printing services. There are tooling costs for design iteration and production. All that is needed is a CAD model(s). According to CGX President Ira Friedman, 3D prototypes and manufacturing eliminated the need for extensive upfront capital to injection mold 200 individual parts.

Our ongoing business relationship with CGX is proof of the advantages to using same 3D printing process and material for product development and production. Contact Us to learn how are 3D printing services can provide you with greater dependability from design to product development and production.


This post was adapted from the SME Article, Growling AM Industry Shows its True Mettle in Covid-19 Pandemic, which includes highlights from Wohlers Report 2021, produced annually by Wohlers Associates. For more information, visit