Case Study: Becton, Dickinson and Company achieves 55% faster print times and 7% less material use with Carbon's Digital Light Synthesis™

Production of Single-Cell Genomic Analysis System Components at BD

Becton, Dickinson and Company (BD) needed a way to produce a complex hemocytometer adapter for the BD Rhapsody™ single-cell genomic analysis system that was impractical and costly to injection mold. Facing difficult-to-mold geometries, long tooling lead times, and a need for rapid design iteration at low initial volumes (~80 units), BD partnered with Carbon to use its Digital Light Synthesis™ technology and MPU 100 medical-grade material to accelerate development and enable production-quality parts.

Carbon worked with BD to redesign the part for printability, rotate internal features for self-supporting walls, apply a functional texture, and implement a custom print script to optimize orientation and throughput. The result: Carbon’s process eliminated supports, cut print time by 55%, reduced resin use by 7%, lowered pre/post-processing labor, and made the hemocytometer adapter BD’s first production part made via additive manufacturing—delivering faster iterations, reduced cost, and production-ready parts.

Becton, Dickinson and Company

Larry Monahan

Manager