Polystar Technologies was established in 2003 after several years of research concluded that new technologies and improved processes could significantly advance the application of porous plastics in the life sciences and biomedical markets. After extensive research into the markets' requirements for porous plastics, it was concluded that customers wanted a supplier offering consistently high product quality and performance, greater responsiveness, personalized customer service, and quicker turnaround. Companies also wanted to be able to procure all of their sintered porous plastics from a single source.

Polystar Technologies believed that there was an opportunity to fulfill these market requirements through the design of new technologies and processes that could significantly improve the quality and expand the applications and uses of porous polymer medias. Although the time invested was substantial, our unique and technologically advanced process has resulted in a robust, reproducible, high-quality result for our customers.  Our proprietary manufacturing process, PolySmart™ , with concept to solution engineering, combines innovations in higher precision tooling, production equipment, processes, adaptive microprocessor controls, and quality analytics.  

Polystar Technologies specializes in the engineering and manufacture of custom, high-quality, specialty porous plastics for the life sciences, medical, consumer, industrial, and many other markets. Our custom, multi-dimensional components are naturally hydrophobic but can be made hydrophilic. Typical pore size ranges from 5µ to 350µ with typical void volumes from 30% to 50% but can be produced with up to 70% void volume.  We take great pride in the quality of our products and in our customers' satisfaction. This is why we closely engineer and control the pore size and void volume through the selection of polymers and process controls. Our porous plastic solutions are manufactured from a wide variety of polymers including:

  • Ultra High Molecular Weight Polyethylene (UHMW-PE)
  • High Density Polyethylene (HDPE)
  • Polytetrafluoroethylene (PTFE)
  • Polypropylene (PP)
  • Polyvinylidene fluoride (PVDF)
  • Nylon 6
  • Polyethersulfone (PES)
  • Polyetherimide (PEI) or ULTEM™ 

The Polystar Technologies Production Process

PolySmart™, our unique product development methodology, encompasses broad-spectrum process improvements and the use of microprocessor-based adaptive controls, resulting in superior deliverables. We have scientifically re-engineered the polymer formulations, tooling, production equipment, processes, process controls, and quality assurance analytics, ensuring our products have robust, high-quality, reproducible results delivered each and every time. These enhancements result in a consistency and reproducibility of process and product quality that is unmatched in the marketplace, giving our customers a superior product. It also creates manufacturing efficiencies that provide a significant contribution to meaningful competitive pricing and shorter lead times, thereby giving Polystar Technologies' customers better products, faster. Because of our drive to produce better-quality products with quicker turnarounds, we are able to provide our customers significantly broader market opportunities.

In 2016, Polystar Technologies, originally headquartered in Fayette County, Georgia, moved operations to our facility in Burnsville, Minnesota, where we continue to create a superior product at a meaningful competitive price, and to develop customer relationships and partnerships to support long-term success. We are dedicated to assisting customers, regardless of size, in discovering business growth opportunities and expanding markets into broader areas.