For decades, Boston has been a global engine for innovation in healthcare and biotechnology. The city has received more National Institutes of Health (NIH) funding than any other over the last 20 years, and is home to one of the highest concentrations of life sciences investment in the world. Boston’s density of research hospitals, universities, and biotech companies has made it a proving ground for new medical technologies — including additive manufacturing (AM).
Industrial 3D printing is being used more widely than ever in healthcare contexts, with applications ranging from personalized medical devices to surgical planning tools and biocompatible implants. The number of U.S. hospitals with dedicated 3D printing facilities grew from fewer than 10 to more than 100 in just a decade, and the global healthcare AM market is projected to exceed $78 billion by 2034.
With its world-class hospitals and academic institutions and strong lineup of AM suppliers, Boston’s life sciences ecosystem is particularly well-positioned to adopt and advance these tools. That advantage is reflected in the work of two Boston-based leaders in healthcare and manufacturing: RAPID + TCT exhibitor Formlabs and Boston Children’s Hospital.
Formlabs: 3D Printing Systems for Clinical Applications
Formlabs was founded in 2011 by three MIT students and has since grown into a major supplier of professional 3D printing systems. The company’s medical portfolio includes stereolithography (SLA) and selective laser sintering (SLS) materials used for patient-specific instruments, cutting guides, and surgeon and patient education models. Applications for these tools range from orthopedics and dental to sleep apnea solutions. During the COVID-19 pandemic, the technology was even used to address shortages of critical components like nasal swabs and ventilator adapters.
Beyond clinical use, Formlabs technology is often used by medical startups during early-stage clinical studies, before transitioning to casting or molding. Industrial 3D printing is well-suited to this phase of research and development because it enables the rapid iteration of parts without the tooling constraints of traditional methods. However, healthcare providers still face significant challenges when introducing additive technologies at the point of care. Bradley Heil, Formlabs’ Global Regulatory and Compliance Leader, pointed to regulatory complexity, inconsistent standards, and the lack of reimbursement codes as persistent barriers to adoption. That makes the company’s collaborations with clinical end users especially important. These partnerships help to demonstrate how these tools are already functioning in real-world settings — and show how other institutions can integrate them into clinical workflows.
Boston Children’s Hospital: Leveraging AM in Pediatrics
One such collaborator is Boston Children’s Hospital, home to the second-largest 3D printing lab in the nation. Among other use cases, the hospital has made headlines for its use of Formlabs systems to print patient-specific cardiovascular models that allow clinicians to test and validate surgical plans before they enter the operating room.
That work is part of a wider evolution happening within the hospital. In the past decade, Boston Children’s Hospital’s Immersive Design Systems team has grown from a simulation-focused program into a full clinical service supporting both physical and virtual training tools. Mariah Latshaw, Manager of Trainer Design and XR, described two primary request types that underpin the team’s workflow. For simulation trainers, clinical teams submit requests when preparing for complex courses, such as extracorporeal membrane oxygenation (ECMO). These procedures often involve dozens of steps and require extremely realistic infant-scale models. In these instances, engineers work directly with clinicians, sometimes over months or years, to iteratively refine and develop highly detailed trainers for internal use.
The hospital also operates a fully-integrated 3D anatomic modeling clinical service. Clinicians can request models through the same system they use for imaging or lab work. This allows engineers to convert patient scans into 3D models, which can be produced as physical prints or delivered virtually. These are most often used for procedures involving rare or complex anatomy, where tailored models help teams focus their surgical approach.
Collaborating to Close Gaps in Care
Industrial 3D printing offers clear advantages in clinical settings. It enables high-mix, low-volume (HMLV) production and iterative design processes that are difficult or impossible to achieve with traditional manufacturing methods. In many cases, it also addresses needs the broader market has left unmet. At Boston Children’s Hospital, for instance, the decision to invest in 3D modeling and printing capabilities was driven by the lack of commercially available pediatric trainers. Bringing these capabilities in-house gave clinicians reliable access to realistic, high-fidelity training solutions. And for the broader industry, the hospital’s learnings are helping to advance healthcare AM as a whole.
RAPID + TCT creates space for that exchange by bringing suppliers and end users together to discuss their experiences. In 2026, RAPID + TCT will include a dedicated Healthcare Showcase, which will feature the latest solutions in personalized care, surgical planning, and biocompatible materials. Meanwhile, in the conference’s specialized healthcare track, expert speakers will discuss new and emerging applications of additive technologies. This programming points to a future in which AM plays an increasingly central role in how healthcare organizations design, plan, and deliver care — for the benefit of clinicians and patients alike.
This article draws on insights from Bradley Heil, Global Regulatory and Compliance Leader at Formlabs, and Mariah Latshaw, Manager of Trainer Design and XR at Boston Children’s Hospital. Formlabs will be an exhibitor at RAPID + TCT 2026, which will take place from April 13 to 16 at the Thomas M. Menino Convention & Exhibition Center in Boston.