For 50 years, the pioneering plastics manufacturer has grown smaller and smaller

CHARLTON, MA– What started 50 years ago as a small tool and die shop has grown into a global leader in a niche industry that didn’t even exist back then. MTD Micro Molding has a long history of investing in innovation to best meet the rapidly changing needs of its customers. It’s a philosophy and strategy that has made them pioneers in plastics manufacturing, helping medical OEMs to successfully produce the smallest and most complex breakthroughs in medical devices.

Richard J. Tully founded MTD, then called Miniature Tool & Die, in the basement of his 200-year-old colonial home in Charlton, Massachusetts in 1972. The main product at the time was manufacturing connector molds for the electronics industry. After investing in new EDM technologies, expanding its capabilities and expanding its operations to multiple locations in Worcester, MTD finally moved into a new 16,500 square foot facility in Charlton in 1998.

MTD has started working on a new niche: micro-injection molding. Very little was known about micro-mold construction or micro-molding at the time, but MTD’s medical OEM customers were quick to encourage the company to explore this area further. With the region rich history in the plastics industry— especially modern injection molding — MTD has successfully attracted top plastics engineers to join its team of expert toolmakers. In 2002, MTD participated in an 18-month Mass MEP assessment to determine if the shift in business focus to micro molding could be sustainable. In 2006, they purchased two molding machines, began work on large-volume bioabsorbable components, and received an NIH Small Business Innovation Research (SBIR) grant to study the microflow of plastics. The investment paid off. In just two years, MTD’s micro-molding business has surpassed micro-tooling for the first time.

Dennis Tully took over the business when his father retired in 2008. In 2010 the company name changed to MTD Micro Molding to reflect its focus on micromolding. Offering both micro-tooling and micro-molding in-house allowed customers to get their micro-components to market faster, which was critical for medical OEMs. To optimize their manufacturing processes, Dennis decided to target BAT even more: medical micro-molding.

Inspired by what his father set in motion, Dennis established MTD’s five core values: to be first, to be the best, to be accountable, to be a team, and always forging ahead.

Like his father, Dennis knew that being “innovative” was not a marketing slogan. This meant continuous investment in technology, capabilities and people, all with the aim of meeting the emerging needs and challenges of their customers. MTD was the first in North America to purchase and customize equipment such as the Sarix EDM milling machine and the Mitsubishi MX600 oil wire EDM machine, enabling the efficient production of medical micro-designs once thought impossible to manufacture. He was the first in his industry to hire a full-time R&D engineer, who is dedicated to exploring new materials and micro-molding capabilities possible. In addition, ten percent of its annual turnover is invested in these internal R&D projects. This has created a strong problem-solving culture at MTD that sees every challenge or “impossible” design as an opportunity to drive innovation forward yet again.

These values ​​have also boosted business. Under Dennis’ leadership, MTD more than doubled its workforce and achieved significant growth, placing MTD on the Inc. List of 5000 fastest growing companies. In 2018, MTD was named Plastics News Processor of the Year, the plastics industry’s most prestigious award, becoming the smallest company to win the title in 22 years. MTD has also been recognized as Plastics News Best Places to Work in Plastics for four consecutive years. And Dennis Tully, who passed away suddenly in 2019, was posthumously inducted into the Plastics Hall of Fame, a distinctive honor given to people around the world who shaped the direction and future of the plastics industry.

This tremendous growth has spurred the building’s expansion in 2021, allowing MTD to further increase its medical manufacturing capacity and add new services, including custom assembly and packaging solutions.

In the future, the next generation of MTD plastics engineers and micro-medicine experts will continue to partner with OEMs to redefine the limits of what is possible.

As CEO Gary Hulecki says, “MTD remains committed to the strategy and values ​​established by Richard and Dennis Tully over the past 50 years. As the demand for even smaller devices with tighter tolerances continues to grow, our team will stay ahead of emerging trends to respond quickly, accurately and efficiently to our customers’ needs and challenges.

Learn more about MTD’s history:—diCa6E

About MTD Micro Molding

Founded in 1972, MTD Micro Molding custom manufactures ultra-precise molded components that meet the exact requirements of companies in the medical device industry. In-house tooling, unparalleled bioresorbable molding expertise, ISO 13485 certified systems, state-of-the-art equipment – ​​all under one roof. Our exclusive focus on bioabsorbable medical and drug delivery micro-molding ensures the successful delivery of complex custom products that no one else can produce.

To learn more, visit or come visit our facilities in Charlton, Mass.

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