Built for Speed: Inside RPM Micro Solutions’ Approach to MedTech Micro Molding

In this episode of MedTech Unboxed, Steve talks with Gary Hulecki, CEO of RPM Micro Solutions, and Mark Bonifacio, Board Member, RPM Micro Solutions, about their approach to helping MedTech teams move complex micro-molded components from design to manufacturing faster.

They discuss how RPM was built around experienced talent, significant equipment investment, in-house tooling, and US-based operations focused on addressing development challenges earlier.

This conversation explores why micro molding requires a different mindset from conventional molding. Gary and Mark dive into how design for manufacturing (DFM), tool design, scientific molding, material behavior, automation, and micron-level metrology must work together from the beginning.

They also discuss implant-grade PEEK, filled polymers, bioresorbables, drug-loaded materials, and why material processing can be just as important as the original formulation.

Get a practical look at how earlier collaboration can reduce development friction, expose design risks sooner, and create a clearer path toward scalable manufacturing.

What you’ll hear in this episode:

• Why micro molding requires closer coordination across part design, tooling, materials, machines, automation, and metrology
• How earlier DFM collaboration can identify difficult-to-mold or difficult-to-measure features before tooling begins
• How in-house tooling and experienced mold design enable faster, more controlled iteration
• The processing challenges associated with PEEK, filled polymers, bioresorbables, and drug-loaded materials
• Why micron-level metrology often means reducing measurement-system noise, not simply measuring the part
• How material characterization and scientific molding can help teams avoid unrealistic designs and costly development setbacks