Creating Quieter, More Productive Spaces to Shout About With Acoustic Metamaterials

Metasonixx, a UK start-up founded by Dr Gianluca Memoli, an acoustics expert with over 20 years of experience, is redefining how sound is managed in shared spaces. By partnering with Protolabs, the company has transformed advanced laboratory technology developed at the Universities of Sussex and Bristol into a scalable product that’s now helping businesses, schools, and even hospitals reduce noise and improve focus.

 

For Dr Gianluca Memoli, acoustics is personal. A long car journey with his children repeatedly playing a popular, repetitive children's song sparked the idea of designing solutions that give each person control over their sound environment.

“Noise-cancelling headphones only work for the wearer,” explains Dr Gianluca Memoli, Founder, Metasonixx. “I wanted to transform spaces so everyone could benefit.”

Metasonixx was born from this vision. Instead of relying on traditional soundproofing materials, the company developed acoustic metamaterials: panels that use the physics of sound itself to cancel unwanted noise. Lightweight, transparent, and reconfigurable, these easy-to-move dividers are designed to improve concentration and privacy without blocking light or isolating people.

However, one of the reasons why we don’t have metamaterials all around us is that it is difficult to produce them in large numbers. Early prototypes were 3D printed, but costs were prohibitive for scaling. To commercialise the product, Metasonixx needed to move to injection moulding — and this is where Protolabs became a critical partner. Protolabs’ unlimited tool offer allows customers to injection mould prototypes with a low tooling price and a higher part price, making access to the technology easy and affordable for developing products via injection moulding. Once the customer is ready to produce finalised parts in higher volumes, they can upgrade to an unlimited tool, where those costs are inverted. A flat fee covers the tool price increase, and the part price is reduced, making larger volumes more cost-effective.

"Protolabs offered us two levels of moulding: one for trials and one for production," says Gianluca. "That flexibility meant we could control costs while producing real parts to put in the hands of customers.”

The collaboration went beyond manufacturing. Protolabs’ engineers helped optimise the complex geometries of metamaterials for moulding, advised on material choices, and guided the transition from acrylic to safer, more durable polycarbonate. The initial designs resulted in slightly hazy visibility through the part, which Gianluca wanted to change to ensure users would not feel isolated. Protolabs reviewed the design and made changes that allowed the space to polish the internal structures, to deliver an SPI Grade A2 polished finish and a translucent part.

“The ability to create meaningful connections with customers, no matter their size, is something that I appreciate about my role at Protolabs,” said Suzie Probert, Account Manager, Protolabs. “In a world where human-to-human interaction can feel limited, it’s refreshing to connect with customers and bring dedicated services to their project. Working with Gianluca is always a pleasure as you really sense his passion for the product.”

Initially, most demand came from customers in industrial spaces where intense noise needed to be mitigated constantly. Thanks to Protolabs, it was possible to make the panels modular, allowing the final shape to be rearranged to suit different situations. Today, Metasonixx products are being adopted across industries. In open-plan offices, they allow employees to concentrate without cutting off visibility. In schools, teachers can mark assignments faster with fewer distractions. Hospitals benefit from their lightweight, moisture-resistant design. Customers range from Chevron and Autostrade per l’Italia to educational institutions and healthcare providers. Collaborations with distributors like STS Isolamenti in Italy have also provided access to manufacturers of luxury products.

"For many years, when you had to design acoustics in an open office, you could only create confinement. Now you can be more creative because finally there’s a solution that doesn’t make you feel like you’re in a coffin." Said Dr Gianluca Memoli, Founder, Metasonixx.

With Protolabs’ manufacturing expertise, Metasonixx has successfully bridged the gap between laboratory innovation and real-world impact.

Challenge

Unwanted noise is everywhere: in offices, schools, hospitals, and even at home. Traditional noise-control solutions are often bulky, opaque, or designed only for individual use, such as noise-cancelling headphones. Metasonixx aimed to develop a lightweight, transparent solution that could provide every individual in a space with the acoustic environment they need — without compromising visibility, flexibility, or design.
Solution
Metasonixx developed desk dividers using acoustic metamaterials — engineered structures that cancel sound waves rather than absorb them. To bring this innovation to market, the company needed a manufacturing partner that could move from small- scale prototypes to scalable injection-moulded parts. Protolabs offered both rapid prototyping and production tooling, helping Metasonixx refine its designs, trial materials, and ultimately manufacture high-quality, transparent panels in polycarbonate.
Outcome

Metasonixx products are now used by companies worldwide, providing acoustic privacy and well-being in open offices, classrooms, hospitals, and industrial sites. With Protolabs’ support, the company scaled from early prototypes to thousands of injection-moulded parts, turning a scientific breakthrough into a commercial success.