DI Labs uses HP Multi Jet Fusion technology to 3D print this surgical face mask in Nylon PA 12 biocompatible material. Image courtesy of DI Labs, Spicer, Minn.
Looking for a supplier of high-quality personal protective equipment (PPE), testing kits, or parts for ventilators? You might want to consider the capabilities of reputable 3D printing service providers.
By Mark Shortt
Out of the devastation of the COVID-19 pandemic is emerging a greater awareness of how 3D printing, or additive manufacturing, can meet critical needs for personal protective equipment (PPE), test swabs, and other medical supplies. Equipment makers HP and Stratasys responded swiftly to shortages by mobilizing global networks of 3D printing designers and operators to mass produce face shields, face masks, mask adjusters, and hands-free door openers. They’ve built a sleeker model of distributed manufacturing that doesn’t need time to tool up. Instead, it turbocharges output while enabling customized parts that can be adapted on the fly.
In April, Design-2-Part surveyed contract manufacturers, job shops, and suppliers throughout North America about their capabilities to manufacture PPE and components for medical supplies during the COVID-19 crisis. Of the 192 companies that completed the survey, 15 reported they provide 3D printing or additive manufacturing services and have the capacity to produce needed medical supplies.
The 15 respondents providing 3D printing services are located in California (5), Tennessee (2), Colorado, Texas, Minnesota, Michigan, Wisconsin, Illinois, Alabama, and Pennsylvania. Following are snapshots of their capabilities, including excerpts from their survey responses, and contact information.
Alabama Reseller Steps into the Breach
When a local medical facility needed more face shields to protect doctors, nurses, and other healthcare workers from COVID-19, a Birmingham, Alabama reseller of 3D printers and supplies stepped into the breach. Prototyping Solutions typically provides Stratasys 3D printers and supplies to medical facilities so that they can produce their own parts, but when a local hospital’s demand for face shields exceeded its supply, the company acted quickly to help resolve the shortage.
“We have several Stratasys FDM 3D Printers in our office and are currently printing about 20 face shield frames for UAB Medical, here in Birmingham,” wrote Travis Coon, vice president of Prototyping Solutions, in response to D2P’s emailed survey. “We have the capability to print respirator adapters as well, but the shield frames have been the priority so far.”
Prototyping Solutions offers 3D printing and scanning equipment, supplies, and services. In addition to Stratasys printers, the company carries the Desktop Metal Studio System™ for metal 3D printing. But as its work for UAB Medical shows, Prototyping Solutions can 3D print critical medical supplies when needed.
“We would consider requests from any essential business, but would likely prioritize helping our local facilities first,” Coon added.
Prototyping Solutions can be reached at 888-220-6293. For those in need of large volumes of supplies, Coon recommended submitting requests to Stratasys at https://go.stratasys.com/lp-stratasys-helps.html.
“This will tap into the huge network that Stratasys has compiled of folks who are able to provide 3D printed supplies [during] this unprecedented crisis,” he said.
Minnesota Company Makes PPE More Protective with Sealed, Sterilizable Parts
A lean and agile product development firm in Spicer, Minnesota responded to the COVID-19 pandemic by quickly pivoting to produce 3D printed face shields, masks, respirators, and components for ventilators. For DI Labs, that means deploying leading-edge additive manufacturing, post-processing, and materials technologies.
“We operate powder-based commercial printing equipment using biocompatible materials and have the world’s only chemical processing system to seal and surface printed parts specifically for medical applications,” DI Labs President Carl Douglass wrote in response to D2P’s survey. “We are able to provide fully functional, sealed, sterilizable parts, in volume, in as little as 12 hours from design submission.”
DI Labs’ stable of 3D printing machines includes HP Multi Jet Fusion printers, as well as Carbon DLS (Digital Light Synthesis) and Markforged Metal X technology. The company combines strong capabilities in additive manufacturing with design for additive manufacturing (DfAM), and engineering services.
The processing system that Douglass referred to is VaporFuse Surfacing, a finishing technique used on 3D printed parts to create smooth, sealed, water-repellent surfaces similar to those produced by injection molding. It provides washable, scratch resistant parts that are suitable for food-contact applications, DI Labs said on its website.
For more on DI Labs, see Minnesota Firm Enlists Additive Manufacturing in Fight Against COVID-19.
Pennsylvania-Made Medical Masks Are Sterilizable, Too
ProtoCAM, in Allentown, Pennsylvania, is an ISO 9001:2015 certified provider of additive manufacturing services that also offers urethane casting and custom finishing. “We have engineers on staff and on call,” wrote ProtoCAM Vice President Bob Holbrook, in response to the survey. Holbrook called “speed to market” one of the firm’s differentiating capabilities for producing high-quality, critical medical parts.
In an update on its website, ProtoCAM said that it is in the process of creating custom medical masks, through a collaboration with local medical facilities, to help combat the spread of COVID-19. The company said it is working with Filament Innovations, a Bethlehem, Pennsylvania based manufacturer of industrial 3D printers, to develop and produce 3D-printed masks.
“The goal for the masks is to produce a reusable, sterilizable protection device that can be cleaned and utilized multiple times, which not only addresses the current reduction in available personal protective equipment nationwide, but also cuts down significantly on waste,” ProtoCAM said on its website. ProtoCAM decided to use HP Multi Jet Fusion printing to produce the masks because of the “technology’s high production output and material availability.”
“The PA Nylon 12 used in the MJF process is biocompatible and can be sterilized, and the technology itself allows for the production of thin-walled features, which helps the mask better conform to the face,” the company said. “The 3D-printed masks are properly fitted to a healthcare worker’s face to form a seal around the nose and mouth, and then go through a comprehensive fit test in order to ensure a proper seal.”
For more information, contact ProtoCAM at 610-261-9010, or visit the firm’s website:
https://www.protocam.com/learningcenter/news/3d-masks-covid-19/
Southern California Firm Partners with HP on FDA-Approved Designs
Forecast 3D’s face shields are worn here by forklift operators. The face shields consist of a 3D printed Nylon PA 12 headband and a clear PET lens, both of which are sterilizable. Image courtesy of Forecast 3D.
In Southern California, a Carlsbad company is producing 3D printed face shields, stop-gap face masks, and mask adjusters, as well as nasopharyngeal swabs, for healthcare professionals and emergency first responders. Forecast 3D, a specialist in 3D printing and custom manufacturing, partnered with HP and medical device suppliers to select specific FDA-approved and NIH-endorsed designs for PPE, the firm said in a release. The company has open capacity to support COVID-19 prevention and containment efforts.
“We are currently producing PPE options designed for quick 3D printing and shipping, for anyone to purchase,” wrote Ashtynn Finney, marketing support specialist, in response to the survey. “We are also working on other custom products for our clients in the battle against COVID-19.”
Forecast 3D is producing the PPE primarily on its HP Multi Jet Fusion machines in Carlsbad. The company said that it plans to add additional lines as approved designs become available. With some 30 HP Multi Jet Fusion printers, the company has “one of the largest HP MJF 3D printing capacities in the United States,” according to Finney. It also offers Direct Metal Laser Sintering (DMLS), stereolithography (SLA), and fused deposition modeling (FDM) services.
“We are proud to be doing our part to help provide critical supplies to the healthcare workers on the front lines of the COVID-19 battle,” said Ken Burns, commercial vice president at Forecast 3D, in a company release. “One of the benefits of additive manufacturing is its ability to adapt to changing product needs. Once we had FDA-approved or NIH-endorsed designs, we accelerated production on these much-needed supplies.”
Forecast 3D is ISO 9001 and AS9100 certified, and is a Tier 1 Stratasys parts provider. In addition to its 3D printing capabilities, the company employs traditional custom manufacturing processes like RTV tooling, cast urethane, and CNC machining.
For more information, contact Forecast 3D at 800-549-5414, or by email at Hello@forecast3D.com.
Suppliers of 3D Printed Parts, from Coast to Coast
Newark, California
Contact:
Sandra Madrigal, CEO and Founder; 650-369-5335; Sandra.madrigal@protocafe.com
Services offered
3D printing (SLA, SLS, multi-jetting); RTV casting, silicone molding, overmolding; laser cutting; painting
Capabilities for producing PPE
3D printing (SLA, SLS, multi-jetting); RTV casting, silicone molding, overmolding; laser cutting; painting
Capabilities to manufacture parts for ventilators or other medical equipment
3D printing (SLA, SLS, multi-jetting); RTV casting, silicone molding, overmolding; laser cutting; painting
Types of parts and services provided to medical industry in the past
3D printing and assembly of face shields; additive manufacturing of short supply, low inventory components for biomedical devices; manufacturing of medical devices for clinical trials; fabrication of healthcare products
Design for manufacturability (DFM)
“Our engineers can discuss design changes that would need to be made for our 3D printing and low volume manufacturing methods,” Madrigal said.
What’s most significant about their offerings?
“Speed and quality. 3D printed parts can be turned in one business day; cast parts, in approximately three to four days,” Madrigal said.
Santa Clara, California
Contact:
Parker Bovenberg, business development; 408-486-6000, ext. 129; pbovenberg@indicate1.com
Services offered
3D printing, 3D scanning, dimensional measurement
Capabilities for producing PPE
3D printing for production parts
Capabilities to manufacture parts for ventilators or other medical equipment
Access to 3D Systems SLS printers, DLP printers, Ultimakers
Current capacity to take on new orders for critical-use parts
Open: 100 parts per day
Ability to repurpose or adapt operations to produce critically needed parts or supplies
Yes
Relevant quality management certifications or registrations
ISO1/IEC 7025:2017
https://indicate1.com/wp-content/uploads/IndicateTechnologiesCertScope-17025-2017-V005.pdf
Types of parts and services provided to medical industry in the past
Currently partnered with 3D Systems and producing face masks, face shields, ventilator parts, and test swabs
What’s most significant about the company’s offerings?
3D printed parts can be measured down to micron level by high end OMM and CMMs to verify accuracy.
Santa Cruz, California
Contact:
Mark Coates, vice president, business development; 949-838-7234; mark.coates@citomedical.com
Services offered
3D printing, milling, assembly, design for manufacturability
Capabilities for producing PPE
3D printing, sewing
Capabilities to manufacture parts for ventilators or other medical equipment
3D printing, machining
Capacity to take on new orders for critical-use parts
Yes
Ability to repurpose or adapt operations to produce critically needed medical parts or supplies
Yes
Relevant quality management certifications or registrations
ISO 13485
Types of parts and services provided to medical industry in the past
Surgical tools, diagnostic and medical devices, lasers
Design for manufacturability (DFM)
Engineers available include mechanical, electrical, and quality
What’s most significant about the company’s offerings?
Quick turn in-house manufacturing and complex design for manufacturing capabilities
Hi-Rel Plastics & Molding, Inc.
Riverside, California
Contact
Mike Kathrotiya, president; 951-354-0258; mike@hirelplastics.com
Services offered
Custom injection and blow molding; part evaluation, engineering, tool design, prototyping, tool making, 3D printing, product assembly services, secondary operations services, plastic and metal machining; decorating, pad printing, hot stamping, ultrasonic insertion and welding, induction coil manufacturing, cable and harness assembly, custom packaging
Capabilities for producing PPE
Same as above
Capabilities to manufacture parts for ventilators or other medical equipment
Same as above
Current capacity to take on new orders for critical-use parts
“We are running at 55 percent capacity and can absorb a lot more work,” said company president Mike Kathrotiya in response to the survey.
Ability to repurpose or adapt operations to produce critically needed medical parts or supplies
“Yes, we can.”
Relevant quality management certifications or registrations
ISO 9001:2015, AS 9100 Rev D, 13485:2016 Certified
What’s most significant about the company’s offerings?
Class 100,000 clean room, in-house tool room, 3D printing, design engineering, quick turnaround, 24/7 production capability, plastics and metal machining
Knoxville, Tennessee
Contact:
Will Lewellyn, director of operations; 865-278-6597; will.lewellyn@millennitek.com
Services offered
3D printing
Capabilities for producing PPE
Face shields, masks, goggles; ventilator valves and splitters
Capabilities to manufacture parts for ventilators or other medical equipment
3D printing
Current capacity to take on new orders for critical-use parts
Yes. Can handle medium size production loads
Ability to repurpose or adapt operations to produce critically needed medical parts or supplies
Yes
Types of parts and services provided to medical industry in the past
3D printed prototypes
What’s most significant about the company’s offerings?
“We specialize in 3D printing and vacuum casting processes, and can handle medium-to-large production loads,” according to Will Lewellyn.
American Mechanized Technology
Chattanooga, Tennessee
Contact
Jeremy Smith, assistant operations manager; 423-661-3925; sales@amt-us.net
Services offered
Engineering, prototyping, short run production (up to roughly 1,000 pieces but as many as 10,000-plus, depending on complexity), 3D printing, assembly, fabrication
Capabilities to manufacture parts for ventilators or other medical equipment
Precision machine equipment, with ID/OD and surface grinding capabilities, and “one of the largest wire EDMs in the area,” according to AMT.
Current capacity to take on new orders for critical-use parts
“We have four mills, two lathes, one dual pallet milling machine, and a wire EDM that could all be set to focus on aiding in this crisis,” said Jeremy Smith, assistant operations manager, in response to the survey.
Ability to repurpose or adapt operations to produce critically needed medical parts or supplies
Yes
Relevant quality management certifications or registrations
“We are ISO 9001:2015 certified and perform 100 percent inspection on all non-production run parts,” Smith said.
Types of parts and services provided to medical industry in the past
Prosthetic components
Design for manufacturability (DFM)
“We employ several highly experienced engineers with a history of design and collaboration experience on projects with real world applications across several industries, including nuclear, hydro power generation, and robotics,” Smith said.
What’s most significant about the company’s offerings?
“We are a high precision machine shop that is used to producing parts with extremely tight tolerances and surface finish requirements for industries such as medical and nuclear,” Smith said.
Paradigm Development Group, Inc.
Winfield, Illinois
Contact
Tony Bastek, sales; 847-545-9600; tonyb@pardev.com
Services offered
Quick turn rapid prototyping of plastic and light duty metals
Capabilities for producing PPE
3D printing, cast urethane, CNC machining
Capabilities to manufacture parts for ventilators or other medical equipment
3D printing, cast urethane, CNC machining
Current capacity to take on new orders for critical-use parts
Yes
Types of parts and services provided to medical industry in the past
Quick turn prototyping of newly designed parts
What’s most significant about the company’s offerings?
Short run urethane molding
Wisconsin Precision Casting Corp.
Lake Geneva, Wisconsin
Contact
Tim Mathers, sales manager; 262-347-4359; timm@wisconsinprecision.com
Services offered
Investment casting in over 150 alloys; rapid prototyping using 3D printed patterns, combined with investment casting to provide metal parts in as few as 10 days with no tooling required
Capabilities for producing PPE
Metal components in over 150 alloys, produced in as few as 10 days with no tooling required
Capabilities to manufacture parts for ventilators or other medical equipment
Metal components in over 150 alloys, produced in as few as 10 days with no tooling required
Current capacity to take on new orders for critical-use parts
Immediate open capacity, with several 3D printers open and ready to produce parts up to a 20-inch cube
Ability to repurpose or adapt operations to produce critically needed medical parts or supplies
Open to produce metal components up to 150 pounds
Relevant quality management certifications or registrations
ISO certified
Types of parts and services provided to medical industry in the past
Stainless steel and aluminum components for a wide variety of medical equipment
Temple, Texas
Contact
Kelly Knake, vice president; 713-907-5801; Kelly.knake@impacsystems.com
Services offered
DFAM training and implementation services; geometric dimensioning and tolerancing (GD&T) training; 3D printing/additive manufacturing in nylon and stainless steel
Capabilities for producing PPE
3D printing/additive manufacturing
Capabilities to manufacture parts for ventilators or other medical equipment
“We are an engineering company. If it moves, we can design it,” said Kelly Knake, vice president.
Current capacity to take on new orders for critical-use parts
“Ready to go.”
Types of parts and services provided to medical industry in the past
Currently producing face shields and hood parts for remote ventilators
What’s most significant about the company’s offerings?
3D printing/additive manufacturing using HP and Desktop Metal printers
Zeeland, Michigan
Contact
Kevin Schulte, director of sales; 616-772-4560; KevinS@broadviewproduct.com
Services offered
Mechanical and manufacturing engineering; CNC machining, 3D printing (FDM and SLA); urethane cast parts; silicone rubber cast parts; composite part and tooling layups; customer painting, custom welding (MIG/TIG); assembly; manufacturing jigs/fixtures; quality control
Capabilities for producing PPE
Same as above
Capabilities to manufacture parts for ventilators or other medical equipment
Same as above
Types of parts and services provided to medical industry in the past
Product engineering; structural analysis; 3D printing, urethane casting; CNC machining; design and fabrication of manufacturing fixtures
For more on Broadview Product Development, see Product Development Firms Stepping Up to Fight COVID-19.
Loveland, Colorado
Contact
Marjaneh Shahravesh, sales and marketing associate; 970-744-4274; mshahravesh@avidpd.com
Services offered
Additive manufacturing (HP Multi Jet Fusion, Photopolymerizaton, Fused Deposition Modeling, SLA)
Capabilities for producing PPE
Additive manufacturing (HP Multi Jet Fusion, Photopolymerizaton, Fused Deposition Modeling, SLA)
For more on Avid Product Development, see Product Development Firms Stepping Up to Fight COVID-19.
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