Case Study: Thaddeus Medical Systems achieves ultra-durable, reusable cold-chain protection with Carbon DLS

Diversified Plastics Manufactures Complex Gyroid Lattice Structure Components for Thaddeus Medical Systems, Inc. with the Carbon DLS™ Process

Thaddeus Medical Systems, founded by Steve Scully, developed the IQ‑ler active cold‑chain packaging to protect temperature‑sensitive medical supplies and specimens from a shipping environment that in 2015 saw nearly 20% loss and about $35 billion in global waste. Existing packaging and 3D‑printed prototypes from other vendors failed to deliver the compliant, flexible, smooth‑finished gyroid lattice the design required, so Thaddeus turned to Carbon and its Carbon DLS™ Digital Light Synthesis process.

Carbon supplied the Carbon DLS™ process (using Carbon’s SIL 30 material) to produce the design‑patented gyroid lattice—manufactured via Diversified Plastics’ Acceleration Station—enabling production‑quality, end‑use parts without tooling and rapid design iteration. The Carbon DLS solution delivered ultra‑durable, reusable IQ‑ler components that damp vibration, maximize airflow for temperature control, and accelerated the product development timeline, positioning the IQ‑ler for beta testing and broader market adoption while reducing waste and lifecycle cost.

Thaddeus Medical Systems

Steve Scully

Founder