The material matters more than the printer.

When discussing additive manufacturing, attention often focuses on the performance of the 3D printer. Print speed, resolution, build volume, and manufacturing technology are frequently highlighted as key factors.

However, in the medical device industry, the success of a project depends first and foremost on the material.

Even when using the same printer and the same manufacturing process, changing the material can completely alter the final device’s performance, durability, and suitability for its intended application.

Choosing a material is therefore far more than selecting a polymer, it means defining the foundation of the future medical device.

Start with the clinical application

Material selection should always begin with the intended clinical use.

Will the device be in contact with the patient’s body? For how long? Will it be temporary or permanent? Will it be sterilized? Will it be subjected to mechanical loads?

The answers to these questions determine the material properties required for the application.

Evaluate the material’s mechanical performance

Each medical device has specific mechanical requirements.

Depending on the application, the material may need to provide:

• flexibility or rigidity;
• impact resistance;
• fatigue resistance;
• dimensional stability;
• wear resistance.

Mechanical performance must remain consistent throughout the product’s lifecycle.

Consider thermal behavior and manufacturing constraints

Not every material behaves the same during additive manufacturing.

Thermal properties influence print quality, dimensional accuracy, repeatability, and overall process robustness.

Selecting a material also means ensuring compatibility with the chosen manufacturing technology and production process.

Ensure compatibility with sterilization

Many medical devices require sterilization before use.

Steam, ethylene oxide, gamma irradiation, or other sterilization methods may affect the material’s properties.

Selecting a material that maintains its performance after sterilization is essential for ensuring safety and reliability.

Never overlook biocompatibility

For devices intended to come into contact with the human body, biocompatibility is a critical consideration.

The selected material must be appropriate for its intended use and compatible with the applicable regulatory requirements.

Biocompatibility should be considered from the earliest stages of development rather than being treated as a final validation step.

Material development as part of innovation

Sometimes, existing materials are not sufficient to meet a project’s specific requirements.

In these cases, developing dedicated formulations or custom filaments may provide the best solution.