Custom Molding
To mitigate the risks associated with inconsistent quality, 86% of the largest medical device companies entrust Freudenberg Medical with the production of their most critical thermoplastic and silicone injection molded components and assembly of complete medical devices.
We have been designing and manufacturing plastic injection molded medical device components and finished devices for more than 30 years. Since then, we have supported hundreds of medical device and IVD manufacturers to bring innovative products to market.
Injection Molding for Medical & Pharmaceutical Applications
Freudenberg Medical offers comprehensive capabilities in the injection molding space, specializing in both thermoplastic and silicone components for the pharmaceutical and medical device sectors.
With manufacturing facilities across North America, Costa Rica, Europe, and Asia, we deliver high-quality products to customers worldwide.
Drug Delivery Products
Freudenberg Medical develops and manufactures components for advanced drug delivery systems: from microneedle patches, syringes, implantable chemotherapy delivery ports and catheters, peristaltic pump tubing and systems to drug coating of minimally- invasive devices and more.
Minimally Invasive Devices
Custom molded applications are often needed across our device product range.
This includes catheter molding for custom handles, over-molding to join catheter tips to plastic, connectors and high-performance valves for catheter systems.
Orthopedics
Our engineering teams have helped mold and extrude components for use in knee, hip, shoulder and other orthopedic surgical solutions.
Our capabilities consist of silicone and thermoplastic two-shot and over molding, providing components for joint replacement and wound repair.
In Vitro Diagnostics
Lateral flow components, point of care devices, diagnostic cartridges.
Freudenberg Medical supplies over 80 million custom molded thermoplastic and silicone parts per year to in-vitro diagnostic OEMs.
Thermoplastic Injection Molding Expertise
We offer a comprehensive range of thermoplastic injection molding solutions—from low- to high-volume production—including micro molding, insert molding, and vertical insert molding across a wide variety of materials such as Polyurethane, PEEK, PET, Pebax, Nylon (Polyamide), Polyolefin, Polyethylene, Polycarbonate, FEP, PVC, PFA, PVA, ABS, and PMMA.
Our expertise includes:
- Two-shot thermoplastic injection molding
- Implantable components using materials like PEEK
- Thin-wall molding for highly precise parts
- Custom thermoplastic components for biopharmaceutical applications
- Advanced hot runner systems (valve gate and open tip) to minimize scrap and lower costs
- Decoupled and closed-loop injection molding processes for consistent quality
We operate top-tier ARBURG, TOYO, and Battenfeld presses ranging from 15 to 350 tons and make extensive use of automation systems for in-line inspection, performance testing, and packaging.
Thermoplastics can vary by supplier and even batch to batch. To ensure the highest quality and consistency, we only work with established suppliers of medical grade thermoplastics. No matter what thermoplastic material your application demands, we understand its unique properties and suitability for specific medical applications.
Silicone Injection Molding Expertise
Freudenberg Medical offers advanced silicone molding solutions for a wide range of medical applications, including ophthalmology, orthopedics, neurosurgery, cardiology, oncology, and ENT. We work with biocompatible and implant-grade silicones using cutting-edge technologies such as Liquid Injection Molding (LIM), transfer molding, two-shot molding, micro molding, insert molding, over-molding, and silicone composite molding.
Our expertise includes:
- Low- to high-volume production
- Short- and long-term implantable silicones (LSR and HCR)
- Thin-wall molding and tight-tolerance silicone bellows
- Flashless, wasteless cold-runner systems
- Fully automated high-cavitation molding
- Precision tooling for consistent part quality
- Comprehensive testing at every stage to ensure safety and performance
We leverage deep engineering expertise and work exclusively with world-class medical-grade silicones from leading suppliers such as NuSil, DuPont, Dow Corning, Momentive, Wacker, Blue Star, and Shin-Etsu.
Our state-of-the-art Arburg, Sumitomo and Engel presses (ranging from 5 to 200 tons) enable high-efficiency, high-precision molding, making Freudenberg Medical a trusted partner for complex silicone components in the most demanding medical and biopharma applications.
Two-Shot Molding
Freudenberg Medical offers advanced two-shot molding capabilities using all-in-one machines with multiple injection units, enabling the seamless integration of different materials into a single component. This process reduces cost, labor, and assembly steps while improving part quality, aesthetics, and functionality.
With expertise in combining hard/hard, hard/soft, and soft/soft materials (including LSR, TPE, polycarbonate, and urethanes), our two-shot molding solutions accelerate production cycles, support modular tooling for low-volume runs, and help consolidate complex part performance into one high-quality, efficient design.
Micro Molding
Our micro-scale products include silicone molded components, weighing as little as 0.004g. We deliver high-precision micro molding solutions for medical applications, including implantable and hybrid components.
This attention to detail is possible through the dedicated efforts of a design and development team who have experience developing technologies for dry eye therapies, glaucoma treatment and drainage, corrective/ocular surgery, and drug delivery systems.
Rely on our …
Quality
State-of-the-art cleanrooms, equipment and controls, ensuring precision and quality through advanced molding processes, including liquid injection molding (LIM), transfer/compression molding, micro-molding, and two-shot molding.
Fewer Component Defects
We are students of the material. Our approach allows us to minimize short shots, weld lines, burns, blush, flashing and other defects.
Lean Manufacturing
We prioritize lean manufacturing, validated processes like Scientific Injection Molding (SIM), and automation systems, enabling us to meet stringent industry standards while driving cost efficiency and minimized scrap.
Reliability
Our focus on customization and validated processes ensures the highest quality and reliability for our customers' medical device and biopharmaceutical needs.
In medical device molding, producing good parts isn’t enough—achieving a stable, repeatable process is. At Freudenberg Medical, we refine one variable at a time, guided by decades of experience and clearly defined process strategies, to eliminate trial-and-error and deliver consistent quality you can rely on.
Doug Thorpe
Senior Director of Process Technology & Engineering
Customer Success Stories
eXciteOSA® by Signifier Medical
Conductive silicone compound for an innovative neuromuscular tongue training device from London-based Signifier Medical Technologies.
Bambi Belt by Bambi Medical
Monitoring of preterm babies, this device contains flexible electronics in a coated silicone belt which replaces sticky electrodes and cumbersome cables.
Minimizing Blood Loss
Freudenberg Medical partnered with a global device leader to develop the next-gen FlexSeal® Hemostasis Valve—delivering superior sealing, usability, and catheter compatibility through fully integrated design and manufacturing.
