Revolutionising Medical Device Development

With Digital Light Synthesis™ technology

About us

When it comes to saving or enhancing lives, continuous breakthrough innovation is paramount. The faster you can get your device to clinical trials, or your model into the surgery, the better the outcome for all.
We have been helping the medical industry to develop innovative devices since 2003. Our broad spectrum of services and technologies support a wide range of materials specifically designed for medical sector.
We’ve helped our medical innovation customers to innovate, develop, test, improve and produce high quality parts. We’ve supported them through concept visualization and design iterations. We’ve given them the tools needed for quick decision-making. We’ve helped them shorten product development cycles. We’ve helped them to find production solutions. We’ve been flexible and kept costs down. And we’ve made sure they’re happy. Time and again.

AM for Medical Device Manufacture

Additive manufacturing (3D printing) applications in the medical innovation field now go way beyond validation prototyping. The advancement of technologies and materials has enabled the development of patient-specific models and devices and volume manufacture of single use items with cost and time efficiencies previously unimagined.
Designers have been leveraging advantages in both new printing software and new resins which has led to a reduction in the number of processing steps and subsequently costs of manufacturing. There is a host of technology for additive manufacturing available to the sector.
Recognising that our clients are on an eternal mission to create products that push boundaries in terms of innovation and performance, in 2018 we invested in 3 Carbon digital manufacturing printers.

Digital Light Synthesis™ Technology

Technically a 3D printing process, Carbon Digital Light Synthesis™ technology (DLS™technology) uses digital light projection, oxygen permeable optics, and programmable liquid resins to produce parts with excellent mechanical properties, resolution, and surface finish. The process creates parts up to 100 times faster than more traditional 3D printing methods. With a wide array of resins specifically designed for end-use, parts printed with Digital Light Synthesis technology are much more like injection-moulded parts.
DLS™ technology is for volume production rather than prototyping. With the medical device market being driven by digital manufacturing, DLS comes into its own for medical devices comprising parts made up of unmouldable, complex geometries; or when a percentage of component parts are modified to enable that device to perform different or multiple functions.
DLS™ technology provides device designers with the freedom to produce multiple variations of such components without incurring significant tooling costs each time an adjustment is made. It provides device designers with an opportunity to produce 1000s of precise copies of each of their final parts with ‘at scale’ pricing. And, with an array of mechanical properties and material choices available, medical device designers and manufacturers can be secure in the knowledge that the parts printed with DLS™ technology are biocompatible (some are sterilisable); and can be adjoined to injection-moulded parts without the worry of mechanical failure.

The Digital Light Synthesis™ Technology advantage

Digital Light Synthesis™technology uses a High Intensity Light shone through an Oxygen Permeable Lens to Cure the resin above.
The subsequent parts with any support structure are attached to the platform
The clever element, and the differential between DLS™ and more traditional 3D printing methods, is that the platform moves away from the lens at a constant speed. This makes parts much stronger -there are no weaknesses between layers; the density of the material is much greater; and the resultant parts’ properties are comparable with injection moulding.
This enables us to print parts which are production intent, from resins which have been produced to withstand a very wide range of conditions.

The Digital Light Synthesis™ Technology difference

Traditional 3D printing methods

3D printed parts are notoriously inconsistent. Their mechanical properties vary depending on the direction the parts were printed due to the layer-by-layer approach.

Digital Light Synthesis™ technology

Parts printed with Digital Light Synthesis™ are much more like injection-moulded parts. Digital Light Synthesis™ produces consistent and predictable mechanical properties, creating parts that are solid on the inside.

Digital Light Synthesis™ Technology applications in the medical sector

Materials Overview

MPU Medical Polyurethane
Biocompatible, sterilisable,

EPU Elastomeric Polyurethane
Highly elastic, resilient

RPU Rigid Polyurethane
Tough and abrasion resistant, stiff

UMA Prototyping Resin
General purpose

EPX Epoxy
Temperature resistant, strong and accurate

CE Cyanate Ester
High temperature resistance, strength, and stiffness

SIL Silicone-urethane
Soft, biocompatible and tear resistant

FPU Flexible Polyurethane
Tough, impact, abrasion resistant with moderate stiffness

Carbon® Materials Bio-compatibility Overview