{"id":17054,"date":"2025-11-02T13:50:50","date_gmt":"2025-11-02T13:50:50","guid":{"rendered":"https:\/\/topat10.com\/?p=17054"},"modified":"2025-11-02T13:50:50","modified_gmt":"2025-11-02T13:50:50","slug":"this-founder-went-from-designing-happy-meal-toys-to-making-prosthetic-skulls-for-a-living-and-her-company-now-rakes-in-20-million-a-year","status":"publish","type":"post","link":"https:\/\/topat10.com\/?p=17054","title":{"rendered":"This founder went from designing Happy Meal toys to making prosthetic skulls for a living\u2014and her company now rakes in $20 million a year"},"content":{"rendered":"\n

Happy Meal toys like Transformer figurines and Hot Wheels cars have sparked joy with little kids for decades\u2014and now, one of the designers behind the miniatures is changing lives for thousands of people. Dallas-based entrepreneur Nancy Hairston founded MedCAD<\/a>, a surgical solutions company, in 2007\u2014and in the decades since, its 3D-printing innovations have helped patients recognize themselves in the mirror again.<\/p>\n

\n

But before Hairston was building skull implants, she spent most of her career in the design world. When she graduated art school with a sculpture MFA from Loyola University in 1991, she had a rude awakening: She couldn\u2019t find any open jobs for what she wanted to pursue. Meanwhile, 3D animation was all the rage at the time, so Hairston pivoted and took on a litany of modeling and animation jobs, from Mary Kay cosmetics to software company Alias. Eventually, she landed in the toy industry. The tactile practice of sculpting in clay was now being done digitally on a computer, which meant designing in 3D\u2014and major corporations were wanting it to manufacture everything from toys to shoes.\u00a0<\/p>\n

\u201cIt was as if a lightning bolt hit me,\u201d Hairston tells Fortune<\/em>, speaking of the first time she entered the 3D-modeling world. \u201cThat was [all] the rage. That was the tool to use. So I started doing Happy Meal toys and Bratz toys for Mattel<\/a>.\u201d<\/p>\n

However, the late 2000s changed things: The entrepreneur says her peers\u2019 roles were all heading to Asia, leaving behind medical and aerospace work as the main points of entry in the U.S. Luckily, Hairston was already recognizing the potential for 3D modeling in healthcare\u2014so she quit her \u201csensible\u201d 9-to-5 job and launched MedCAD.\u00a0<\/p>\n

\u201cIt was thrilling and scary, but I saw the opportunity because the technology was so new,\u201d Hairston recalls.<\/p>\n

The call from a surgeon that changed Hairston\u2019s life<\/h2>\n

She had already started tinkering with anatomy modeling, adapting the toy-development software she\u2019d used for orthognathic surgery applications like jaw and teeth repairs. By the time 2009 came around, she built a business plan to get FDA clearance. And younger surgeons\u2014who grew up exposed to advanced tech and 3D animation, Hairston says\u2014were starting to take note as word spread of her innovations.<\/p>\n

Then, Hairston\u2019s phone rang. The ensuing call would alter the trajectory of her career.\u00a0<\/p>\n

\u201c[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, \u2018Hey, you know, do you think you could make me a cranial implant?\u2019\u201d Hairston says. \u201cAnd that\u2019s how it started.\u201d<\/p>\n

MedCAD went on to fill the unmet needs of patients with small to large deformities stemming from trauma-related injuries or physical abnormalities. Skull implants have continued to be a huge part of the business, but the company has since expanded into other areas of the body such as foot, ankle, and facial reconstruction products, all conceptualized with 3D designs.\u00a0<\/p>\n

\u201cWe were some of the earliest people doing it,\u201d Hairston continues. \u201cThere\u2019s 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\u2019s the power of this technology\u2014we can do a more holistic approach to reconstructing a foot or a face.\u201d<\/p>\n

Scaling MedCAD to upwards of $20 million in annual revenue<\/h2>\n

Since founding MedCAD nearly two decades ago, the company has continued to grow in the 3D-implant space. The company tells Fortune<\/em> it has achieved profitability and boasts an annual revenue estimated to be between $10 million and $20 million this year and in 2026, but did not specify exactly how much it\u2019s making in annual profit. Cranial and neuro products are a key growth driver, experiencing 18% to 25% growth year-over-year since 2022. It\u2019s also ramping up a direct-to-hospital strategy, but a majority of its revenue comes from long-term contracts with global medical leaders needing implants and medical devices.\u00a0<\/p>\n

Despite having a successful run in toy-designing and founding a profitable business, Hairston says she\u2019s most energized by the difference her implants make in peoples\u2019 lives. Sparking joy among little kids with her McDonald\u2019s toys and Bratz dolls was one achievement, but she\u2019s making even more waves for thousands of medical patients hoping to feel whole again.\u00a0<\/p>\n

\u201cToys are really fun for children, but they\u2019re not played with for long,\u201d Hairston says. \u201cWe 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.\u201d\n<\/p>\n<\/div>\n\n","protected":false},"excerpt":{"rendered":"

Happy Meal toys like Transformer figurines and Hot Wheels cars have sparked joy with little kids for decades\u2014and now, one of the designers behind the miniatures is changing lives for thousands of people. Dallas-based entrepreneur Nancy Hairston founded MedCAD, a surgical solutions company, in 2007\u2014and in the decades since, its 3D-printing innovations have helped patients […]<\/p>\n","protected":false},"author":791,"featured_media":17055,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_uag_custom_page_level_css":"","_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[123],"tags":[],"class_list":["post-17054","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-business"],"yoast_head":"\nThis founder went from designing Happy Meal toys to making prosthetic skulls for a living\u2014and her company now rakes in $20 million a year | Unlock Informed Choices with Us<\/title>\n<meta name=\"description\" content=\"Entrepreneur Nancy Hairston founded 3D medical-design company MedCAD after designing McDonald\u2019s Happy Meal toys and Bratz dolls.\" \/>\n<meta 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