At James Cook Hospital in Middlesbrough, our prosthetics and orthodontics laboratory plays a vital role in helping patients recover from trauma, cancer, or congenital conditions. Every day, we design and create medical devices—from orthodontic retainers and sleep apnea appliances to complex facial prosthetics—that restore function and confidence for our patients. Recently, our lab underwent a significant transformation with the introduction of the Mayku Multiplier pressure forming machine, a change that has dramatically improved our workflow, efficiency, and patient care.

Breaking Free from Bottlenecks

Before we acquired the Multiplier, our production process was constrained by the limitations of a single pressure forming machine. Only one model could be processed at a time, which meant technicians spent long hours repeating the same steps: placing a model, inserting a blank, waiting for the cycle to finish, and then starting again. This repetitive process not only slowed down our output but also tied up skilled staff who could have been contributing elsewhere in the lab.

With the Multiplier, we can now pressure form up to a dozen models simultaneously. This leap in capacity has eliminated the bottleneck in our workflow. Instead of waiting for each device to finish, our technicians can now prepare multiple cases at once, freeing up their time for other critical tasks such as designing custom solutions, refining device fit, or collaborating with clinicians on complex cases.

Consistent Results, Every Time

Reliability and consistency are crucial in medical device manufacturing. The Multiplier delivers perfectly formed devices with every cycle, regardless of material type or size. Whether we’re making a delicate retainer or a robust facial prosthesis, we know we’ll get a high-quality result. This consistency means we no longer waste time or materials on rework, which was sometimes necessary with our previous equipment.

The machine’s versatility has also allowed us to experiment with a broader range of materials and device sizes. Its large forming area and compatibility with different plastics mean we can take on new, more challenging cases—further enhancing the services we offer to our patients.

Staff Satisfaction and Professional Growth

The impact on our team has been profound. The monotonous, repetitive work has been replaced by more engaging, meaningful tasks. Our technicians now have the opportunity to develop new skills, explore innovative approaches, and focus on complex, rewarding aspects of their profession. This has led to higher job satisfaction and a more motivated team.

Moreover, the efficiency gains mean we can respond more quickly to urgent cases, reduce waiting times for patients, and handle a greater volume of work without increasing staff workload. All of this contributes to a more positive, dynamic work environment.

A Smart Investment with Immediate Returns

From the outset, it was clear that investing in the Multiplier would quickly pay off. The time and cost savings from increased efficiency and reduced rework were immediately apparent. Our hospital administration recognized these benefits and supported the purchase, understanding that it would ultimately improve patient care and make the best use of NHS resources.

Transforming Patient Care

Ultimately, the most important outcome is the impact on our patients. Every device we produce has the potential to change someone’s life—restoring their ability to eat, speak, breathe, or simply smile with confidence. The Multiplier allows us to deliver these life-changing devices more quickly and reliably than ever before.

When I see the positive difference our work makes for patients, I feel a deep sense of pride and fulfillment. The new technology has not only made our jobs easier but has also enhanced the care we provide, reinforcing the value of what we do every day.

Key Achievements at a Glance

  • Significantly increased processing capacity by forming multiple models at once
  • Expanded production capabilities for a wide range of medical devices, including orthodontic retainers, sleep apnea appliances, face masks, and custom prosthetics
  • Delivered consistent, high-quality results across all device types and materials
  • Achieved rapid return on investment through greater efficiency and reduced rework
  • Boosted staff satisfaction by enabling more meaningful, less repetitive work

Enhanced patient care by shortening turnaround times and improving device quality

Looking Ahead

The success of the Mayku Multiplier at James Cook Hospital demonstrates the transformative potential of investing in advanced manufacturing technologies within the NHS. By streamlining production, empowering staff, and delivering better outcomes for patients, we are setting a new standard for prosthetics and orthodontics labs across the country.