Research & Development

What has R&D been up to in 2020?

We know that innovation requires hard work and expertise, and we channel this into our dedication to creating groundbreaking solutions.  Here are some ways our skilled R&D team has been working to advance our capabilities.

Developed and implemented Tessy proprietary laser welding processes utilizing enhanced optics combined with custom mirrors to weld multiple assemblies simultaneously on a high speed 150 part-per-minute medical assembly line, leading to improved cycle times and dramatically reducing the quantity of laser systems and labor required for the given cycle time.

Enhanced performance of microfluidic medical devices with a combination of precision molding, Tessy proprietary ultrasonic processing, and the utilization of precision tool manufacturing for high precision micro-channels to sub .002” accuracy followed by ultrasonic processing to .0005” accuracy as required.

Developed a proprietary ultrasonic forming process for generic polycarbonate materials, eliminating assembly components, post processing operations, and the requirement for higher cost custom blended polycarbonate materials.

machine with computer

Many medical products require mass flow, pressure decay, and other means of critical product testing. Tessy has deployed Cincinnati Test Systems’ Blackbelt Pros as standard test equipment, offering superior test capability. The R&D team integrates CTS devices into manual and semi-automated test platforms, performing multiple tests to a single assembly providing rapid testing.

Developed Tessy proprietary micro-assembly cells to drive automation advancements in tandem with in-process automation builds. These cells drive process development and identify processes or design issues early, saving customers’ capital and critical product launch milestones.

Initiated internal project partnering with Tessy Tooling to build our first prototype metal injection molding (MIM) tool. Tools are due the 1st quarter of 2021 and will introduce a MIM part in replacement of an existing part in a surgical medical device.

employee working with computer microscope

Developed technology to blend ratios of post-consumer resin and virgin material to deliver a recycled product that does not require tooling changes. We accomplished this by identifying ways to purify PCR while maintaining material properties and utilizing the recycled resin across a multitude of applications – ultimately keeping the recycling loop continuous. 

Created resins that emulate physical properties of Polypropylene (Homogenous and Co-Polymers) as well as Low Density Polyethylene to produce biodegradable products.

Research & Development Tools and Equipment


  • SLA 3D Printers
  • FDM 3D Printers
  • Polyjet Multi-material & Color 3D Printer
  • 5-axis CNC Milling Machine
  • Lathe


  • Environmental Chamber
  • 3D Microscope
  • Camera Vision System
  • Tension/Compression Force Testers
  • Material Moisture Analyzer


  • Molding Machines
  • LSR Machine


  • Ultrasonic Welder
  • Laser Welder
  • Laser Marker-Engraver
  • Heat Stake Machine
  • Soldering-Electronics Workstation
  • Liquid Dispensing Station
  • Flame/Plasma Treaters