Case Study: Activated Research Company achieves rapid, production-ready Polyarc™ microreactor development with Protolabs metal 3D printing

Activated Research Company chose Protolabs’ metal 3D printing process to produce functional parts for its award-winning reactor

Activated Research Company, a catalyst start‑up in Eden Prairie, Minn., developed the Polyarc™ catalytic microreactor to rapidly and cheaply quantify carbon‑containing chemicals in GC‑FID systems. Faced with the need for a compact, gas‑tight stainless‑steel block with intricate internal channels and precise thermal control—features traditional machining couldn't produce—they partnered with Protolabs and used its direct metal laser sintering (DMLS) metal 3D‑printing service for prototyping and production.

Protolabs’ DMLS delivered laser‑sintered parts typically in under a week, enabling more than 20 rapid design iterations to achieve the final 2"×1" reactor with integrated channels, heater and sensors; Activated Research Company now uses those DMLS parts in end‑use production and benefits from Protolabs’ fast quoting and reorder workflow. The Polyarc™ reactor launched in 2015, won the Gulf Coast Conference Best New Product Award, and Protolabs’ metal 3D printing materially sped development, preserved critical flow and thermal performance, and helped scale a high‑value product to market.

Activated Research Company

Andrew Jones

Partner and Co-Founder