DJO Inc Shortens Design Cycles By More Than 25 Percent Using SolidWorks Software

CONCORD, Mass – Can a knee brace be a fashion statement? If so, DJO Inc. may be America’s next great designer.

The U.S. leader in orthopedic rehabilitation devices is using SolidWorks® software to make knee braces and other products highly functional to address medical needs, as well as lighter, more comfortable, and aesthetically pleasing. Since adopting SolidWorks The San Diego based company has brought increased speed, agility, and quality to R&D supported by advanced capabilities like 3D modeling and simulation.

For example, DJO is using SolidWorks to:

* create stylish surfaces and contours while working with carbon fiber, metals, and a variety of plastics that make braces sleeker, less “medical” in appearance, and less intrusive to the end-user;
* shorten design cycles by more than 25 percent through SolidWorks software’s intuitive modeling;
* reduce development costs – for example, saving 5 to 10 percent, or thousands of dollars, on each major project – by using SolidWorks Simulation software to lessen the need for numerous physical iterative prototypes; and
* develop product-specific literature and manuals by using PhotoWorks realistic rendering software to create studio-class product “shots” prior to manufacturing.

“SolidWorks was an easy transition from the 2D-only design world and is a superior tool for meeting the product needs of both elite athletes and weekend warriors,” said Robert Bejarano, R&D senior project manager. “We use SolidWorks for all design, surfacing, rendering, and simulation across many of our product lines, including rigid bracing, surgical implants, electrical stimulation technology, and bone-growth systems. It is amazing how versatile this software has been during the development stage.”

DJO has used SolidWorks extensively on several new product releases each year across many product lines. One example is a new breakthrough knee brace that promotes faster healing after surgery. While most post-operative braces simply limit range of motion, the new DonJoy® TROM Adjuster™ unloads the knee compartment and associated injured tissue so it heals faster and reduces the potential of re-injury post-surgically. This brace offers an easily adjustable hinge with “Tele-Fit™” telescoping technology for a perfect patient fit. SolidWorks Simulation software enabled Bejarano, a former NASA engineer, to quickly test parts as he designed them and to optimize use of material for sleekness and cost control.

DJO knee braces are used by more than 90 percent of Division 1 college football teams and 61 of the 68 teams in the latest round of college bowls. DJO brace users include:

* big wave surfing champion Garrett McNamara
* motocross rider Brett Metcalfe
* U.S. Ski Team mogul skier Shannon Bahrke
* freestyle mogul skier Jillian Vogtli
* U.S. Snowboard Team member Nate Holland
* Canadian mogul skier Kristi Richards
* Green Bay Packers offensive linemen Mark Tauscher and Chad Clifton
* Swedish Ice Hockey player Mattias Timander
* Italian Motocross rider Antonio Cairoli
* Cincinnati Bengals quarterback Carson Palmer
* San Diego Chargers defensive end Shawne Merriman

DJO relies on authorized SolidWorks reseller GoEngineer for ongoing software training, implementation, and support.