Case Study: This carbon-composite orthopedic table met the rigidity and minimal flex requirements of an advanced Hip Distraction System

Here's a case of how we used composites to solve a medical application through a collaborative effort between our Composite Resources team and our client.

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For this project, our team was tasked with developing lightweight components for carbon composite orthopedic tables, supporting an advanced Hip Distraction System.

The client required a smooth cosmetic finish along with precision stiffness and stability… and in turn requiring a high level of precision for the design and parts assembly. Our Composite Resources team was able to deliver on all counts.

  • Carbon fiber was the material of choice for these components because its fatigue resistance, stiffness and strength made it preferable to more traditional metals.
  • We created a rigid, lightweight support structure that provides maximum rigidity and minimal flex. This both reduces weight and ensures that distraction forces are not lost within the system.
  • The product has tooled outer and inner surfaces to consistently hold tight tolerances required for this application. 


Customer supplied Composite Resources with 3D CAD models.


  • CNC Ply Cutting
  • Prepreg Layup
  • Trapped Rubber Molding Process
  • Out of Autoclave Cured
  • Adhesive Bonding of Assembly
  • Post Assembly CNC Machining
  • CMM Quality Inspection


We were able to meet all client specifications, reduced the overall weight of the orthopedic tables considerably, and were able to move from prototyping to full-scale production in a matter of months — necessary for complying with the client’s rapid-launch timeline.

This orthopedic spar is just one example of what our team can do. Consider how this approach could support an advanced carbon composite surgical table, for example.

Request a no-cost consultation on our custom composites for medical applications:

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