From Prototype to Production: Elite Mold Tech Assists with Small-Batch Custom Manufacturing of VR Headsets for Medical Applications

In healthcare, VR headsets are evolving from "future technology" into real-world diagnosis and treatment scenarios, demonstrating significant potential particularly in rehabilitation training. They can not only assist in treating mental health issues like anxiety and post-traumatic stress disorder, but also play a key role in neurorehabilitation, pain management, and motor function recovery. For example:

With technological advancements, the demand for personalized and highly stable medical-grade VR devices is becoming increasingly prominent. However, transitioning from design implementation to small-batch production is often a key challenge for startups and R&D teams. Today, using Elite Mold Tech's recently completed "custom medical rehabilitation VR headset" project as an example, we'll share how professional CNC rapid prototyping services can streamline the entire process from prototyping to small-batch production.

1. Project Overview: Focusing on Medical Rehabilitation, Addressing the Pain Points of "Small-Batch Production"

1.1 Project Core Information

Category	Details
Service Industry	Healthcare (Psychological Rehabilitation)
Product Positioning	Professional VR headset for psychological and neurological rehabilitation
Core Requirements	50 prototypes for verification + 500 units for small-batch production
Key Technologies	CNC metal processing, plastics processing, vacuum casting, rapid aluminum injection molding
Main Materials	AL6061 aluminum alloy, ABS+PC composite
Surface Treatment	Professional painting and anodizing
Lead Time	15 days for prototyping + 30 days for small-batch production

1.2 Client Challenge

This client is a startup specializing in the mental health field. Their VR headset needs to meet the stringent standards of medical settings—ensuring structural stability and comfort while maintaining cost control for small-batch production. Before the project began, the client faced two key challenges:

Elite Mold Tech, with over 10 years of experience in CNC rapid prototyping and custom machining, provided the client with an end-to-end solution (from design evaluation → prototyping → assembly verification → small-batch production), ultimately enabling efficient project implementation.

2. Prototype Verification Phase: Accurate Selection Paves the Way for Mass Production

The core goal of prototype verification is to identify design issues and verify process feasibility. Overlooking details at this stage can lead to rework risks in subsequent mass production. We provided the client with a cost-effective prototype solution through three key steps:

2.1 Step 1: Design Evaluation to Prevent Manufacturing Risks

After the client provided complete design drawings, our engineering team conducted a comprehensive analysis:

Based on this analysis, we provided the client with three Design for Manufacturability (DFM) recommendations (e.g., optimizing plastic wall thickness to 1.2mm, adjusting the angle of the metal assembly interface) to reduce subsequent manufacturing challenges from the outset.

2.2 Step 2: Material and Process Selection – Balancing Cost, Precision, and Efficiency

Production-grade molds are not required during the prototype phase, so process selection needs greater flexibility. We developed separate plans for metal and plastic parts:

Metal Parts (6 in total)

Plastic Parts (44 in total)

CNC machining 50 sets (2,200 plastic parts total) would take over 20 days and be costly. We recommended vacuum casting (using resin material with properties similar to ABS) for the following advantages:

2.3 Step 3: Assembly Verification to Preemptively Address "Fitness Issues"

After completing part processing, we did not proceed directly to surface treatment—instead, we conducted pre-assembly testing (a crucial detail in the prototype stage):

After re-production and further verification, all parts fit correctly. Finally, after surface treatment (anodizing for metal parts, professional painting for plastic parts), 50 prototypes were delivered to the customer within 15 days. Testing showed 100% functional compliance and a 9.5/10 aesthetic satisfaction rating.

3. Small-Batch Production Phase: Flexible Processing, Cost Reduction, and Efficiency Improvement

The customer highly praised the prototype quality. After optimizing the design, a small-batch production run of 500 sets was initiated. The key focus of this phase was upgrading the prototype process to accommodate small-batch requirements—ensuring cost control and production efficiency to avoid market launch delays.

3.1 Metal Parts: Adhering to CNC Machining, Rejecting Ineffective Costs

Typically, die casting is the preferred process for mass production of 500+ aluminum alloy parts. However, this project only required 200 metal parts. Using die-casting molds would cost 30,000-50,000 yuan, which—when spread across 200 parts—would significantly increase the per-part cost.

Therefore, we recommended continuing with CNC machining and improved efficiency through two optimizations:

Ultimately, the per-part cost was 20% lower than that of a die-cast solution.

3.2 Plastic Parts: Rapid Aluminum Mold Injection Molding to Prepare for Future Mass Production

The production of 500 sets of plastic parts (44 units/set) totals 22,000 units. While vacuum casting is cost-effective, it has limited mold life (each silicone mold can produce a maximum of 20 parts)—requiring 1,100 molds. This is not only inefficient but also risks inconsistent part dimensions due to mold variations.

Given the client’s limited budget and potential future production expansion needs, we recommended the rapid aluminum mold injection molding process for three core advantages:

3.3 Final Outcome

All parts for 500 VR headsets were produced, assembled, and quality-checked within 30 days. After delivery to the customer, the products successfully passed medical trial testing—laying the foundation for subsequent market launch.

Project Summary: Elite Mold Tech, Your Partner from Prototype to Production

From 50 prototypes to small-batch production of 500 sets, Elite Mold Tech always prioritizes customer needs. Through professional process selection and cost control, we help clients overcome three key challenges:

Whether you’re a medical startup or an R&D team requiring customized processing, Elite Mold Tech leverages core technologies (CNC metal processing, plastics processing, vacuum casting, rapid aluminum molds) to provide you with end-to-end solutions from design to post-processing. For more customized processing solutions, please contact us:

Elite Mold Tech, quickly bring your innovative designs to life!