When three visionary medical students launched PolyUnity in 2018, they weren’t just starting a company, they were reshaping the future of healthcare. Founded in Newfoundland and Labrador, PolyUnity began with a big idea: to use 3D printing and digital manufacturing to make healthcare more personalized, accessible, and resilient. Fast forward a few years, and this small start-up has grown into a national health-tech leader by improving care across Canada, one 3D model at a time.
PolyUnity’s roots trace back to a simple but powerful realization: medical students Stephen Ryan, Micheal Bartellas, and Travis Pickett saw how slow, expensive, and inefficient traditional healthcare manufacturing could be. Their solution? Bring manufacturing closer to the point of care using advanced 3D printing technology. By launching additive manufacturing hubs in St. John’s and Ottawa by 2021, and later their i3D.Health software platform, they turned that vision into a scalable reality.
One of PolyUnity’s many standout solutions in the med-tech world is their 3D printed bolus service for radiation therapy. Traditionally, patients undergoing cancer treatment had to endure uncomfortable plaster molds, sometimes across multiple appointments, which is especially challenging for those in rural areas. PolyUnity transformed this process by using CT scans to design precise 3D-printed molds, completely eliminating the need for plaster casting. The result? A quicker, less stressful experience for patients and a 75% reduction in treatment prep time.
At the heart of PolyUnity’s work is their i3D.Health platform, a digital inventory of more than 600 3D printable healthcare tools. The catalogue spans everything from custom patient-specific solutions that improve quality of care to simple, practical replacement parts that keep essential equipment in service. By digitizing and centralizing these resources, PolyUnity enables hospitals and clinicians to bypass traditional supply chain delays and respond to patient needs faster. The platform is also dynamic—users can request new items, track the status of existing orders, and collaborate directly with PolyUnity’s team in real time. It’s not just a library of designs; it’s a responsive ecosystem that connects innovation with frontline healthcare delivery. It’s healthcare manufacturing made smarter, more agile, and more accessible.
St. John’s, Newfoundland & Labrador isn’t just PolyUnity’s headquarters, it’s the company’s heartbeat. Their largest production site is based there, and they’re proud to hire local talent and mentor student interns across disciplines. Their early partnership with Eastern Health has become a national showcase, earning them recognition as the 2023 CAN Health (Coordinated Accessible National Health Network) Company of the Year.
PolyUnity’s future is all about scaling smart. With contracts underway in NL and Ontario, and partnerships growing from coast to coast, they’re expanding fast. New tech is also on the horizon: AI powered tools, smarter design platforms, and advanced materials integration. Their goal? Make innovation in healthcare faster, safer, and more accessible than ever.
Story written by Athena Warren.
