For more than a century, one family-owned specialty manufacturer made a name for itself for masterful problem solving, turning ideas into workable realities. But as the company looked toward the next 100 years, it needed to lean into new capabilities to continue its track record of success. As it turns out, their next big breakthrough was being developed right around the corner at the University at Buffalo.

Tapecon, Inc. is a specialty manufacturer that integrates printing, converting, and advanced materials expertise to deliver high-performance components for medical devices, electronics, aerospace and industrial equipment. The company is recognized for solving complex engineering challenges and transforming innovative designs into scalable, high-quality production.  

For years, Tapecon has maintained a strong relationship with the UB, collaborating with faculty on numerous industry–academic projects and regularly participating in the CMI Career Experience program for students.

As part of its strategic growth plan, Tapecon is expanding its portfolio of healthcare-related sensor applications, leveraging its unique technical capabilities as a key market differentiator. This shift, says Tapecon President Steven Davis, is completely market driven.

“We’re evolving to meet our customers’ needs,” he explains. “Many have grown to become or have been acquired by leading life sciences companies that we’re continuing to serve with our core capabilities in specialized printing. The U.S. continues to be a global leader in life sciences, and it’s a great space for us to be.”

To satisfy customers and sharpen its competitive advantage, Tapecon sought to collaborate more closely with UB. In 2024, the company hosted a showcase event at the university and invited faculty to share current research projects that aligned with Tapecon’s manufacturing capabilities. In return, researchers would have unprecedented access to company resources including investment, development, prototyping and commercialization needed to bring their ideas from concept to market-ready solutions.

At the event, Tapecon met Filip Stefanovic, PhD, assistant professor of biomedical engineering at the Jacobs School of Medicine and Biomedical Sciences. Stefanovic is developing a high-density, wearable sensor to measure muscle activity, the first of its kind small enough to adhere directly to the skin. With Tapecon’s manufacturing support and medical-grade adhesive technologies, together they could significantly accelerate development of a wearable sensor to monitor neuromuscular function in real time.

“As an academic researcher, there are limitations to what you can do in house,” explains Stefanovic. “We were ordering prototypes online from an overseas manufacturer with long wait times. Tapecon is right next door, giving us local capabilities, quicker turnarounds and closer partnership. They already have technology for attaching devices to the human body—it would’ve taken me a long time to develop a solution they already have."

From day one, Tapecon and Stefanovic’s collaboration has taken off toward a shared goal: to create the first stick-to-skin, wearable multichannel electromyography (EMG) amplifier and matrix EMG electrode for muscle performance assessment. These high-density sensors can measure neural activity previously possible only with surgically implanted electrodes. Current multichannel amplifiers are often bulky and limit mobility, hindering their use in real-world applications.

By engineering a novel hardware architecture using amplifier multiplexing, the team seeks to reduce the size of EMG amplifiers so they can be embedded on small, flexible circuit boards that attach directly to the body. This innovation has the potential to transform EMG usability for monitoring and assessing neuromuscular function in contexts such as post-stroke therapy, astronaut readiness after gravitational transitions and athletic performance measurement.

Together, Tapecon and Stefanovic have earned Faculty-industry Applied Research (FIAR) funding through BEP’s Center of Excellence in Materials Informatics (CMI), a project of NYS Department of Economic Development, to continue development and testing of the device. A provisional patent has been filed, and development continues with the help of Stefanovic’s graduate students, one of which has been hired by Tapecon.

The team completed the NY NSF I-Corps program to develop a business case. Tapecon is motivated to advance the project further, having identified several interested stakeholders through I-Corps, including personal trainers, physical therapists and professional athletes. Collaboration efforts also include grant submissions to secure further funding, and Tapecon has expressed interest in licensing the patent and intends to commercialize the product.