Medtech Is in a Period of Chaotic Change. Here’s What Your Company Must Do to SucceedMedtech Is in a Period of Chaotic Change. Here’s What Your Company Must Do to Succeed

Editor’s note: Nicholas Webb, the author of this article, is scheduled to be the opening keynote speaker at MD&M West, North America’s most comprehensive manufacturing trade show focusing on the medtech, plastics, automation, and design and manufacturing industry sectors. MD&M West returns to Anaheim, CA, on Feb. 4 to 6, 2025.

Over my 40 years in the medical device industry, I’ve witnessed distinct phases of industrial change.

The first phase of industrial change was incremental, where improvements in plastics, injection molding, and other manufacturing methods were slow but steady. This phase focused on refining existing processes rather than introducing groundbreaking advances, earning it the label of "incremental phase of innovation."

Around 30 years ago, the industry shifted to a phase of disruptive innovation. This era was characterized by rapid advances and significant changes in how medical devices were designed and manufactured. However, today we find ourselves in an era of chaotic change. While the pace of innovation remains fast, the complexity has increased, and the shifts are more unpredictable. 

Chaotic change poses both challenges and opportunities for manufacturers, especially those utilizing plastics. The demand for new devices and production methods has never been greater, and those who can adapt will be the ones to thrive. In fact, I predict that we will see rapid growth opportunities across all aspects of plastics and plastics manufacturing. In my consulting firm, we track more than 500 trends shaping the industry. This article also provides fresh research for my just-released book, Chaotic Change, which catalogs key changes within the industry. While it’s impossible to explore all of them here, I’ve highlighted the most critical trends in medical-grade plastics and devices for 2025 and beyond.

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Healthcare industry trends

The medical device industry is heavily influenced by overarching industrial trends, which encompass factors such as economic conditions, healthcare access, the political landscape, reimbursement policies, consumer behavior, the decentralization of care, and much more. Amid these complex dynamics, a few key trends stand out as critical for 2025.

The first is the political landscape, where efforts to reduce government spending are expected to have a significant impact on healthcare. Since the majority of healthcare costs are funded by government programs, these cost-cutting initiatives will likely drive changes across the sector.

The second major trend is what I refer to as The Big Shift — a transition from high levels of treatment intervention to a growing emphasis on prevention and wellness. Some experts estimate that up to 80% of healthcare costs are tied to lifestyle-related diseases, where poor dietary habits and sedentary behavior lead to chronic conditions. Proposed government initiatives aim to redirect substantial resources toward prevention and wellness, with the ultimate goal of reducing reliance on costly treatment-based care. This trend is so pervasive that three years ago I produced a film, The Healthcare Cure, that catalogs in more detail the impact of the transition from treatment-centric policies to prevention and wellness policies.

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Additionally, the consumerization of healthcare continues to reshape the industry. Patients increasingly view healthcare products as consumer goods and expect solutions — whether at-home injectables or other medical devices — to be affordable, functional, and safe. We will see significant opportunities in plastics, as we develop more tech for at-home use and in healthcare and point-of-care settings.

With these global trends in mind, here are the key trends in medical devices and plastics that will define the industry in the coming years.

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3D, 4D, and 5D printing for medical devices

Additive manufacturing is transforming the production of medical devices. While 3D printing has become relatively commonplace, new technologies will enable custom, patient-specific implants and prototypes.

Another exciting area lies in 4D and 5D printing. With 4D printing, materials can adapt to stimuli such as heat or pressure, adding functionality that goes beyond static structures. Meanwhile, 5D printing allows for the creation of highly precise, multi-dimensional components that are stronger, more efficient, and capable of addressing complex medical applications.

One of the most underexplored aspects of this trend is the convergence of 3D printing with artificial intelligence (AI). This integration will enable machines to optimize production and experimentation autonomously, reducing reliance on human intervention. While today’s 3D printers are often rudimentary, we can expect significant advances over the next five years. 

Another area that is gaining traction is the combination of 3D printing and robotics. This will allow organizations to produce multiple plastic, metallic, and elastomeric components, and then have the robotic arm do all the subassembly work. This would allow for an integrated production process. Companies must prepare by integrating these technologies into their innovation pipelines to remain competitive.

Small shot and precision molding

While wearable technologies continue to gain traction, the next major wave will focus on implantable medical devices. These technologies, capable of performing tasks such as continuous blood sampling and precision drug delivery, demand highly precise and small-scale components. These extremely small parts are often referred to as micro, or nano, components.

Traditional large-scale production equipment often fails to meet the accuracy requirements for such intricate parts because of machine chatter and other challenges. As a result, leading manufacturers are investing in specialized capabilities — small-shot production, precision molding, and controlled environment molding. Techniques like liquid injection molding (LIM) are also gaining popularity. To keep pace with these advances, organizations must assess their production infrastructure and make the necessary upgrades to align with emerging trends.

Smart materials for enhanced functionality

The emergence of smart materials is revolutionizing the medical plastics landscape. These advanced polymers are designed to sense, react, and adapt to external conditions, enabling functionalities such as biofeedback and antimicrobial and self-healing properties. Additionally, smart materials are being developed to monitor inflammatory responses to implants and validate device functionality, making them integral to the next generation of medical devices.

To stay competitive, companies should establish cross-disciplinary "future-casting" teams that include material scientists, plastics experts, and data analysts. These teams should meet regularly to evaluate new materials and technologies, ensuring that their innovation pipelines remain robust and aligned with market demands.

Sustainability in medical plastics

Sustainability is no longer optional in the medical plastics industry. Innovations such as recyclable materials, single-use devices, and autoclavable plastics are leading the way in reducing the flow of medical plastics into the waste stream. Bio-based polymers and biodegradable plastics are also becoming viable alternatives for addressing environmental concerns. 

Engineers are also leveraging structural ribs and other design features to reduce the overall shot size without compromising structural rigidity and functionality. The key challenge will be the need to make certain that the component materials meet the stringent guidelines of the FDA to ensure their safety and effectiveness. Depending on their application, recycled materials and biopolymers represent a greater challenge to the medical device industry.

Achieving true sustainability requires a strategic, systematic approach. Organizations must explore opportunities to minimize waste by downsizing materials, and incorporating recyclable components. Building cross-functional teams to evaluate these opportunities can help develop actionable, measurable plans that drive long-term environmental and economic benefits.

Staffing and the changing workforce

The workforce dynamic has shifted significantly, influenced by a multigenerational population with evolving priorities. Today’s employees value exceptional workplace experiences over traditional compensation models. In my book, Happy Work, I outline "Happiness as a Strategy" (HaaS), a concept that emphasizes creating positive work environments to enhance employee retention, engagement, and productivity.

Companies that prioritize employee satisfaction and cultivate a culture of happiness not only attract and retain top talent but also drive innovation and revenue growth. Developing thoughtful strategies to support and inspire critical talent is essential for long-term success in a competitive market.

The superpower of enterprise innovation

In today’s fast-changing environment, enterprise innovation has become a necessity. This discipline involves leveraging innovation methods across an ecosystem that includes employees, customers, distributors, and vendors. Organizations that embrace enterprise innovation consistently outperform their peers, achieving up to 60% greater success in meeting strategic goals.

While leaders may hesitate to add more initiatives to their already busy agendas, the benefits of enterprise innovation are well worth the investment. With the right team and approach, companies can reduce costs by as much as 30% while significantly improving their adaptability and overall performance.

Success requires rapid adoption of new best practices and technologies

The medical device industry will see major changes over the next five years. Companies must decide whether to resist change or embrace innovation. In my consulting work, I find that organizations and leaders can be categorized into four groups as it relates to their openness to change — Protectors, Observers, Innovators, and Disruptors.

Protectors

Protectors are organizations that are deeply resistant to change. They often rely on outdated strategies and technologies, believing that their current methods are sufficient to maintain stability and profitability. However, this reluctance to adapt puts them at significant risk. As the market evolves and competitors embrace new innovations, Protectors frequently find themselves unable to keep pace with changing customer demands or industry standards. Over time, their resistance to change can lead to stagnation, loss of market share, and eventual displacement by more agile competitors. These organizations typically prioritize maintaining the status quo over pursuing growth opportunities, which can be a dangerous strategy in fast-moving industries.

Observers

Observers are organizations that recognize emerging trends but are hesitant to act on them. While they may invest time and resources in monitoring market developments, their cautious approach often leads to delayed decision-making. This reluctance to commit to new strategies or technologies means that they frequently miss out on first-mover advantages and risk falling behind more proactive competitors. Observers tend to adopt innovations only after they have been widely proven by others, which can result in a loss of momentum and a diminished competitive edge. While they are aware of the need for change, their slow response can limit their ability to capitalize on opportunities in a timely manner.

Innovators

Innovators are proactive organizations that embrace change and prioritize staying ahead of the curve. These companies actively seek out emerging technologies, trends, and strategies to integrate into their operations, ensuring they remain relevant and competitive. Innovators are not afraid to take calculated risks, often investing in research and development to create unique solutions tailored to market needs. By fostering creativity and a forward-thinking culture, they are able to drive growth, improve efficiency, and maintain a strong position within their industries. Innovators understand that continuous improvement and adaptability are essential to thriving in an ever-changing landscape.

Disruptors

Disruptors are the visionaries who redefine industries by challenging conventional practices and introducing groundbreaking innovations. These organizations do more than just adapt — they actively shape the future of their markets. Disruptors combine emerging technologies, bold strategies, and creative problem-solving to deliver solutions that set them apart from competitors. Their willingness to push boundaries and embrace transformative change allows them to capture significant market share and redefine customer expectations. By taking a leadership role in driving innovation, Disruptors inspire other organizations to rethink their approaches and contribute to the ongoing evolution of their industries.

Industry leaders always fall in the category of Innovators or Disruptors. I always recommend that organizations leverage a future readiness team to ensure they’re staying ahead of the curve. This requires more than just being aware of change — it truly requires thoughtful, formal strategies with meaningful KPIs.

The future of plastics and plastic processing holds incredible promise. With advances such as AI and robotic process automation, and emerging market opportunities, manufacturers can significantly reduce costs — potentially by as much as 30% — while enhancing efficiency and precision. By adopting Enterprise Innovation methods, organizations have the opportunity to improve strategic outcomes by up to 60%, driving both operational success and long-term growth. 

Furthermore, the development of new materials and cutting-edge manufacturing processes is poised to revolutionize healthcare. These innovations will enable a shift from costly, intervention-heavy treatments to a proactive focus on prevention and wellness, ultimately improving quality of life and delivering better patient outcomes.

The path forward is filled with opportunity, but success will depend on the willingness of organizations to embrace change, adopt emerging technologies, and align their strategies with the evolving demands of the market.