Rapido industry case studies

Surgical implants designed and manufactured to precisely fit an individual’s anatomy can reduce operation times and improve patient outcomes.

The usual design of personalised surgical products is complex and time-consuming, involving highly skilled personnel and detailed surgeon input.

Stryker needed a digital platform to streamline the design of patient-specific surgical solutions using 3D printing.

We used expertise in 3D geometry processing, a technique that creates precise 3D computer models of real objects using a combination of applied mathematics, computer science and engineering, to develop an advanced software solution.

An automated software platform for virtual surgical planning, enabling users to easily design surgical models, implants, and bone cutting guides for 3D printing.

A reduced burden on highly specialised overseas design personnel, and accelerated access to treatment for patients.

The current findings and future iterations of this work have the potential for significant international impact.

The Rapido team were asked to investigate opportunities to build a bespoke 3D printing prototype with the capability to custom-print gravity spirals of up to 3 metres tall.

One of the key objectives was to print without support material, thereby minimising material costs and manufacturing time.

The project commenced with a feasibility study to confirm 3D printing as the preferred manufacturing process and to determine the optimal printer configuration for printing the target part.

The solution developed by the Rapido team leveraged non-planar 3D printing to achieve this with a bespoke machine configuration paired with a purpose-built custom slicing algorithm optimised for the creation of the target parts.

The result is Sidewinder, a bespoke 3D printer prototype that can produce customised spirals for different target ore bodies. 

Sidewinder enhances the accuracy of the mineral separation process, increasing mining yields and improving the quality of the resulting mineral concentrates.

It has the potential to decentralise the spiral production process and ship the printer to where new spirals are needed at that time.

UTS researchers needed a working prototype to demonstrate how quantum computing could be made accessible to non-specialists.

UTS Rapido was engaged to translate early-stage research into a functional, manufacturable device that could support learning, experimentation and future commercialisation.

• Translated a complex quantum emulator onto a Raspberry Pi, built a mobile onboarding app, developed a cloud-based quantum circuit builder, and designed an elegant aluminium enclosure.
• Worked with UTS researchers to develop the early Quokka prototype, combining multi-disciplinary R&D expertise.
• A multi-disciplinary approach helped transform advanced research into a consumer-ready quantum product, used to learn and experiment with quantum coding.

• Translated early quantum research into a testable, real-world product:

• Brought together mechatronics, software and UX teams to deliver integrated R&D.
• Accelerated the transition from lab-based research to functional prototype.
• Enabled testing, iteration and demonstration through small-batch manufacturing of a commercially viable proof of concept.
• Contributed to the successful launch of Quokka, the first 30-qubit consumer quantum computer emulator.

Modelling, testing and prototyping of a potential conveyor sortation system utilising a new omni directional wheel, designed for commercial use to help optimise sortation logistics, reduce breakdowns, downtime and costs.

Digital twin modelling was needed to simulate outcomes from different configurations and help understand the disruption potential of the OMNIA wheel in the logistics sector.

• A digital twin of the OMNIA wheel-powered conveyor system was developed to model the different points at which packages came into contact with the wheels.
• Conducted a series of tests to measure roller friction, traction and compression, seeking to understand how a package would move based on its weight and materials, as well as on a variety of wheel orientations and speeds.
• A prototype sortation table was built, comprised of 115 OMNIA wheels and repeated the tests using more than 20 different scenarios were conducted to verify the outcomes of their computer-based modelling.

The testing paved the way to the development of OMNIA’s Omni Directional Sortation System, a sortation table that can be used as an independent cell or integrated into complex, networked conveyor systems.

Unlike standard sortation systems, which often use roller belts, swivels or pneumatic components, the OMNIA system is based on two different sizes of omni wheels arranged at 90 degrees to one another.

It can be used as an independent unit for multidirectional diversion and sortation or combined with other units to complete complex tasks such as RFID scanning, printing and labelling.

The project aimed to apply machine learning to model Zurich’s existing underwriting approach, improve decision consistency, and identify the key questions that influence outcomes, with the goal of simplifying the application process.

Applications involving mental health disclosures often required additional information such as a doctor's report, which could delay decisions by up to 22 days. 

The project sought to streamline this through AI models that support faster, more consistent underwriting.

• The models were trained on seven years of anonymised application data. 

• Developed 10 machine learning models using logistic regression, decision trees and XGBoost
• Addressed any sparse datasets by handling incomplete application responses across a large question set
• Achieved over 80% prediction accuracy across all models
• Applied novel unsupervised learning techniques to compare Zurich’s customer cohorts with the broader Australian population, uncovering new cohort characteristic insights not visible in Zurich’s internal data

We developed AI models capable of making immediate decisions on applications with mental health disclosures, without requiring external medical reports. 

The AI models will be used to verify decisions made by Zurich’s underwriting team and the existing rules engines they use, in keeping with Zurich’s AI philosophy to ‘always keep a human in the loop’.

We explored a novel wireless energy harvesting system capable of safely extracting usable power from the magnetic field of high-voltage powerlines, eliminating the necessity for a direct physical connection.

We developed an advanced proof-of-concept prototype and secured additional funding to progress to the next stage.

We collaborated with Professor Dylan Lu and the UTS School of Electrical and Data Engineering to develop an advanced proof-of-concept prototype.

• The proof-of-concept prototype has been tested in the lab, demonstrating its ability to wirelessly harvest energy from high-voltage powerlines.
• The intention is to conduct field testing with the enhanced v2 prototype, which aims to incorporate improvements in efficiency, durability, and environmental resilience.
• The next stage of the project has secured seed funding under the NSW Electrification & Energy Systems Network (EESN) Seed Grant Scheme, a key initiative of the NSW Decarbonisation Innovation Hub.

PolySpine’s wearable exoskeleton supports people with limited mobility, but it needed to meet strict safety and performance standards for TGA approval.

They lacked the specialist facilities and engineering expertise required for compliance testing and validation.

Designed and delivered a full validation testing program using university-grade labs and equipment.

Tests covered strength, durability, flammability, toxicity, and product lifespan.

The results led to design improvements and provided the evidence needed for regulatory approval.

PolySpine met the stringent medical device compliance standards and confidently moved into commercial production.

The device passed all required safety and performance tests, secured ARTG approval in 2021, and launched the following year.

Now listed on the NDIS and under review by the US FDA, PolySpine is enhancing mobility and inclusion for users nationwide.

Added key product improvements and the creation of two new jobs.