Comfortable Meal toys like Transformer collectible figurines and Scorching Wheels vehicles have sparked pleasure with little youngsters for many years—and now, one of many designers behind the miniatures is altering lives for 1000’s of individuals. Dallas-based entrepreneur Nancy Hairston based MedCAD, a surgical options firm, in 2007—and within the many years since, its 3D-printing improvements have helped sufferers acknowledge themselves within the mirror once more.
However earlier than Hairston was constructing cranium implants, she spent most of her profession within the design world. When she graduated artwork faculty with a sculpture MFA from Loyola College in 1991, she had a impolite awakening: She couldn’t discover any open jobs for what she needed to pursue. In the meantime, 3D animation was all the fashion on the time, so Hairston pivoted and took on a litany of modeling and animation jobs, from Mary Kay cosmetics to software program firm Alias. Finally, she landed within the toy business. The tactile follow of sculpting in clay was now being executed digitally on a pc, which meant designing in 3D—and main firms had been wanting it to fabricate all the things from toys to sneakers.
“It was as if a lightning bolt hit me,” Hairston tells Fortune, talking of the primary time she entered the 3D-modeling world. “That was [all] the rage. That was the tool to use. So I started doing Happy Meal toys and Bratz toys for Mattel.”
Nonetheless, the late 2000s modified issues: The entrepreneur says her friends’ roles had been all heading to Asia, forsaking medical and aerospace work as the details of entry within the U.S. Fortunately, Hairston was already recognizing the potential for 3D modeling in healthcare—so she stop her “sensible” 9-to-5 job and launched MedCAD.
“It was thrilling and scary, but I saw the opportunity because the technology was so new,” Hairston remembers.
The decision from a surgeon that modified Hairston’s life
She had already began tinkering with anatomy modeling, adapting the toy-development software program she’d used for orthognathic surgical procedure purposes like jaw and enamel repairs. By the point 2009 got here round, she constructed a marketing strategy to get FDA clearance. And youthful surgeons—who grew up uncovered to superior tech and 3D animation, Hairston says—had been beginning to take notice as phrase unfold of her improvements.
Then, Hairston’s telephone rang. The following name would alter the trajectory of her profession.
“[I had] one of those pivotal moments in your life, where your whole world changes. I got a phone call from a surgeon that I knew, and he said, ‘Hey, you know, do you think you could make me a cranial implant?’” Hairston says. “And that’s how it started.”
MedCAD went on to fill the unmet wants of sufferers with small to giant deformities stemming from trauma-related accidents or bodily abnormalities. Cranium implants have continued to be an enormous a part of the enterprise, however the firm has since expanded into different areas of the physique resembling foot, ankle, and facial reconstruction merchandise, all conceptualized with 3D designs.
“We were some of the earliest people doing it,” Hairston continues. “There’s a fantastic thread to all of this is, that we are able to bring a person back as much as we can to a normalized state with a lot less surgeries. [Patients are] waking up with the ability to have teeth implants after they heal. That’s the power of this technology—we can do a more holistic approach to reconstructing a foot or a face.”
Scaling MedCAD to upwards of $20 million in annual income
Since founding MedCAD almost twenty years in the past, the corporate has continued to develop within the 3D-implant house. The corporate tells Fortune it has achieved profitability and boasts an annual income estimated to be between $10 million and $20 million this yr and in 2026, however didn’t specify precisely how a lot it’s making in annual revenue. Cranial and neuro merchandise are a key development driver, experiencing 18% to 25% development year-over-year since 2022. It’s additionally ramping up a direct-to-hospital technique, however a majority of its income comes from long-term contracts with world medical leaders needing implants and medical units.
Regardless of having a profitable run in toy-designing and founding a worthwhile enterprise, Hairston says she’s most energized by the distinction her implants make in peoples’ lives. Sparking pleasure amongst little youngsters together with her McDonald’s toys and Bratz dolls was one achievement, however she’s making much more waves for 1000’s of medical sufferers hoping to really feel entire once more.
“Toys are really fun for children, but they’re not played with for long,” Hairston says. “We can really make a difference making these kinds of products for humans that change their lives. That gave me a lot of the power and the passion to do it.”
