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Quality is a centerpiece for Polymer Medical, which is why Harp says the new company has invested in its quality management systems, in part, to meet ISO 13485:2016 standards for medical devices. After analysis by Polymer Medical’s degreed engineers and RJG Master Molder® qualified technicians and managers, Harp’s employees will produce customers’ designs in ISO-7 and ISO-8 clean manufacturing environments. The company also provides cleanroom assembly and packaging.

“There’s a rising demand for medical devices partly because of changes in demographics and approaches to home healthcare; the time is right for a new entrant like Polymer Medical,” says Harp, president of Polymer Medical. “Our knowledge of the specifications and science of producing polymers for healthcare and bioscience along with what we understand about delivering product quality and innovation give us a competitive edge.”

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“Tom and I have more than 50 years of experience,” Harp adds. “The decision to found Polymer Medical was done after careful consideration of the landscape and market opportunity; we will raise the level of competition and quality for customers.”

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Orchard Park, N.Y.-based Polymer Medical is a world-class provider of contract plastic injection molding and assembly for healthcare and biosciences. Its services include in-house tool building, tool transfer, product enhancement, and finished medical device assembly. For more information, visit https://polymermedical.com/

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“When a client comes to us, we’ll provide Design for Manufacturing analysis to offer ways to improve on what they’re already trusting us to make,” adds Rybicki, vice president of Operations for Polymer Medical. “When we take an order from a customer, we assess their tool, or mold, for those big or small things that could disrupt production. That saves money for the customer and ensures quality.”

The system is powered by a new print engine that uses a tech called LFD (Low Force Display) to cure the parts at higher speeds. That’s coupled with an increased build area, which allows users to print more small parts simultaneously.

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Looks like Formlabs really dogfooded this one, using the Form 3 to prototype parts for its successor. The is up for pre-order today, starting at $4,499. It’s set to start shipping on May. The healthcare-focused Form 4B, meanwhile, starts at $6,299.

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According to an array of analyst reports, researchers expect the medical polymers market to grow at a compound annual growth rate of more than five percent through 2030, reaching more than $30 billion. Harp and Rybicki also believe North American customers are more eager than before the pandemic to favor U.S.-based providers for their supply chain. The field is already packed with competition, but Harp and Rybicki see Polymer Medical’s creativity, design know-how, process control, and tooling expertise as critical differentiators.

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Founded in 2011, Formlabs represents a rare prolonged success story in the world of desktop 3D printing. That’s due in no small part to the underlying stereolithography printing, which to that point, had been the domain of massive and wildly expensive industrial 3D printing.

ORCHARD PARK, N.Y.  – Plastics industry veterans Benjamin Harp and Tom Rybicki have launched Polymer Medical Inc. to provide healthcare and biosciences clients with contract injection-molding and assembly services. The new company’s focus will be producing critical drug-delivery systems, medical disposables like syringes, medical devices for home healthcare to orthopedics, specialty packaging, and pharmaceutical disposables among other services. Harp and Rybicki each have decades of experience founding and operating plastics industry manufacturers for healthcare, pharmaceuticals, and nutraceuticals.

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Since then, the company has gone on to become a mainstay in the world of rapid prototyping. It has also increasingly pushed into the medical realm. In March 2020, for instance, systems were deployed to print out nasal swabs for COVID-19 testing. Dental has been an important market for the company, as well, owing to the level of customization offered by additive manufacturing.

This month marks five years since the release of the Form 3, Formlabs’ last major 3D printer refresh. To celebrate the occasion, the MIT spinoff has unveiled the long-awaited Form 4. At the top of the notable features list are faster printing speeds (under two hours for most prints, per the company), a 30% build volume increase and a print resolution the company claims rivals injection molding.

“Fast print speeds do not compromise on dimensional accuracy or surface finish,” Formlabs says in a release. The Form 4’s print quality is nearly indistinguishable from traditional manufacturing methods, such as injection molding, making it the ultimate 3D printer to maximize productivity, move production in-house, and enable users to take more design risks.”

Polymer Medical Vice President of Operations Tom Rybicki (left) and President Benjamin Harp stand in one of the soon-to-be-equipped certified ISO cleanrooms of Polymer Medical’s manufacturing facility. [Photo courtesy of Polymer Medical]

Fittingly, Formlabs says it was able to print 11 dental models in nine minutes and 130 dental crowns in just 20 minutes.

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