Device Manufacturing

Delivering high-quality, consistent results across every stage of device manufacturing.

With vertically integrated capabilities, global production sites, and a lean approach rooted in continuous improvement, we help bring efficiency and reliability to your supply chain. Our commitment to quality, speed, and scalability makes us a trusted partner for companies seeking reliable, long-term manufacturing support.

Materials Expertise

As a global group, we bring deep technological and materials expertise to the processing of thermoplastics, silicone, coatings and metals for medical device and biopharma customers worldwide. 

Our team supports customers in selecting the optimal materials for their applications. Long-standing partnerships with trusted suppliers ensure reliable access to high-quality, medical-grade raw materials.


Our Capabilities

Catheters


Freudenberg Medical offers unsurpassed expertise in the design, development, and manufacture of minimally invasive surgical and catheter-based devices. Our product development and manufacturing teams collaborate to ensure design for manufacturability, decreased development time, and increased speed to market for finished goods.

Our solutions meet a diverse set of market needs across a variety of clinical focus areas including cardiovascular, electrophysiology, neurology and neurovascular, peripheral vascular and structural heart.

Our ELECTROPHYSIOLOGY Catheter Capabilites at a glance

Our Catheter Capabilities in detail:

Handle and Shaft Development


Complete Partner for Proximal Handle Design and Manufacturing.


From concept to production, we offer comprehensive support in catheter handle development. Our capabilities span industrial design, mechanical design for manufacturability, and ergonomic optimization with a focus on human factors.

 

We work closely with customers to ensure design alignment with procedural requirements and user needs. Rapid prototyping through 3D printing enables quick iteration and accelerates development timelines.

 

Discover our Design & Development

 

handle shaft design drawings
smiling catheter lab team

Catheter Assembly


End-to-end catheter assembly—from design, material selection and prototyping to extrusion, braid reinforcement, balloon forming and metal component integration for high-performance, reliable devices.

We understand that each catheter must undergo rigorous validation and qualification, followed by proper sterilization, packaging, and labeling, to meet the exacting standards of today’s minimally invasive therapies. Whether it’s a braid-reinforced guidewire or a complex multi-lumen system, our team works side-by-side with you to ensure your product not only performs as intended but also reaches patients safely and on time.

 

Discover our Lean Manufacturing

 

Catheter Extrusion & Finishing


Advanced extrusion with precision braiding and coiling for consistent, complex catheter designs. Careful control of the extrusion process ensures consistency and repeatability.

We deliver a comprehensive suite of catheter finishing capabilities to support the development of high-performance medical devices. From insert and overmolding to annealing, tip forming, and fusing, our processes are designed to enhance catheter functionality and reliability.

 

We provide precision techniques such as adhesive bonding, laser cutting, hole drilling, and punching, while also offering specialized services like catheter reinforcing and hydrophilic coatings to optimize performance.

 

Discover our Customizable Solutions

 

catheter extrusion lab room
evaluating balloon capabilities

Balloon Capabilities


Advanced balloon catheter development with in-house extrusion, rapid prototyping, and custom balloon design. 

With expertise in compliant, semi-compliant, and non-compliant balloon technologies across various materials and dimensions, we support a range of clinical applications. Our Balloon Development Center delivers precision, tight tolerances, and fast turnaround times for high-performance, low-profile, and high-pressure balloons tailored to specific performance needs.

 

Discover our Custom Extrusions

 

Hypotubes & Metal Components


Leading supplier of advanced hypotubes, pullwires, assemblies and products for minimally invasive devices used in diagnostic and therapeutic interventions.

 

We supply over 10 million components annually to 70+ OEMs worldwide, supporting everything from prototyping to high-volume production. Whether you need enhanced steerability, strength, or precision, we’ll help you move from concept to market with confidence. Freudenberg also develops and manufactures stylets, cannulas, and high-precision specialty needles used in vascular and endovascular access, biopsy, and drug delivery procedures.

 

Discover our Metal Capabilities

 

detailed closeup of hypotube metal component

Implantable Solutions

 

We offer implantable medical device solutions in long-term implantable silicone material as well as implantable-grade PEEK polymers. Both applications are suitable for long-term implantation in the human body, longer than 29 days.

 

Our implantable product solutions are manufactured in ISO 13485 certified facilities within ISO certified cleanrooms. If your product requires compliance with stringent regulatory requirements, specific facilities are in compliance with FDA, European MDD, and Health Canada requirements as well as equipped with ISO Class 7 & 8 cleanrooms.

Implantable Silicone Solutions


With decades of experience, Freudenberg Medical is a trusted manufacturer for long-term implantable silicone solutions. 


As one of the few US and Germany based companies processing long-term implantable silicone, we combine precision, safety, and proven performance. Devices range from peritoneal dialysis shunts, gastric bands, and reflux stop devices, pacemaker leads and cochlear implant components.

 

Discover our Custom Molding Capabilities

 

implantable reflux stop
implantable peek solution

Implantable PEEK Solutions


Freudenberg Medical offers precision manufacturing of implantable-grade PEEK components for demanding medical applications. 


Known for its strength, biocompatibility, and stability, PEEK enables complex, high-performance designs for orthopedic, cardiovascular, spinal, and dental implants. With injection molding expertise, we deliver cost-effective solutions without the need for secondary processing.
 

Discover our Custom Molding Capabilities

 

Smart Medical Devices


Integrating electronics with biocompatible materials is complex—Freudenberg Medical makes it possible. From electrically conductive silicone to encapsulated components, we turn your smart device vision into reality.

With deep expertise in materials, injection molding, custom extrusion, and device assembly, we ensure reliable performance, quality, and patient safety in connected and wearable medical technologies.

Customer Success Stories

  • eXciteOSA® by Signifier Medical product

    eXciteOSA® by Signifier Medical


    Conductive silicone compound for an innovative neuromuscular tongue training device from London-based Signifier Medical Technologies.
     

    Discover more

  • newborn baby

    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.
     

    Discover more

Freudenberg Medical Facility

PARTNER WITH
FREUDENBERG MEDICAL


For over three decades, we have been at the forefront of innovation when it comes to delivering high-quality solutions from ideation and market launch to volume production for medical device and pharmaceutical companies. 

 

Our team of 200+ engineers provides integrated development and assembly manufacturing that supplements and accelerates an OEM’s ability to deliver quality products to market quickly. With proven expertise in materials and technologies, Freudenberg Medical offers an extensive range of vertically integrated capabilities: precision molding and extrusions, complex catheters, hypotubes, and coatings.

 

Together, let's get patients the treatment they need.

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