Medical Device Manufacturing Capabilities

Shaping solutions that rise above the ordinary.

Various plastic packaging components in white and blue, including trays, containers, and lids, arranged on a gray surface.

Compression Molding

Compression molding uses heat and pressure to shape foam materials into three-dimensional, contoured parts. UFP MedTech commonly compression molds cross-linked polyethylene (XLPE) foam for applications such as orthopedic components, patient cushioning, and protective packaging, where consistent shape, fit, and performance are important.

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Thermoplastic Welding

For over a half a century, UFP MedTech has built its reputation as the go-to source for thermoplastic welding of medical devices. It is the preferred method over gluing or hot air due to the creation of very robust hermetic seals.

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High-Speed Die Cutting

High-speed die cutting converts foams, films, plastics, and composites into precise components at production scale, holding tight tolerances across high-volume runs. This process supports a wide range of medical applications, including infection control components and protective packaging inserts, where consistent, repeatable cuts are essential. UFP MedTech's die cutting capabilities are built to scale from prototype runs to full production volumes without compromising quality.

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Vacuum Forming

Vacuum forming shapes rigid plastics including PETG, PETE, and ABS into precise trays, clamshell packaging, and device housings. This capability is well suited to sterilization-compatible packaging formats, giving device manufacturers a reliable way to protect components through sterilization and distribution. Explore the full range of rigid plastic materials UFP MedTech works with for vacuum-formed applications.

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Thin film thermoformed medical device components

Thin Film Thermoforming

Offered through Welch Fluorocarbon, a UFP Technologies company, thin film thermoforming converts ultra-thin, high-performance thermoplastic films into complex three-dimensional shapes with precision tolerances and rapid prototyping. The process is ideal for medical applications requiring dielectric insulation, temperature and chemical resistance, inertness, and non-stick surfaces.

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Injection Molding

Offered through TPI, a UFP Technologies company, injection molding delivers high-quality, precision components for medical device applications. This process is ideal for producing complex, tight-tolerance parts at scale, including micro components, with consistent quality and cost efficiency.

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Cut and Sew

Offered through AJR Specialty Products, a UFP Technologies company, cut and sew provides high-quality, scalable solutions for medical applications. With extensive sewing capabilities and rigorous quality assurance, AJR produces custom textile components with exceptional precision, efficiency, and reliable lead times.

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Fluid & Air Management

Fluid and air management capabilities support devices that move, contain, or control fluid and airflow including NPWT (negative pressure wound therapy) systems, catheter fluid management, and surgical draping fluid channels. UFP MedTech works with films, foams, composites, and tubing to engineer components that maintain reliable fluid pathways and pressure control across single-use and reusable device designs.

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Clear plastic medical device with blue and white connectors, tubes, and a handle, viewed from above.

Tube Finishing

Tube finishing prepares tubing for integration into finished devices through processes including hole punching, cutting, machining, printing, and insert molding. UFP MedTech works with PVC, silicone, and polyurethane tubing to support applications such as catheters and fluid management systems. Precision finishing ensures tubing meets the dimensional and functional requirements of the final device assembly.

Tube Finishing

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Lamination

Lamination bonds two or more material layers to create multifunctional composite constructions. UFP MedTech combines foams, films, fabrics, adhesives, and other materials to support applications such as orthopedic soft goods, patient positioning devices, protective packaging, and device cushioning. By combining complementary material properties, lamination can improve comfort, protection, durability, and manufacturability.

Lamination

FlexShield by UPD Technologies, a translucent blue protective cover, displayed on a light background.

Printing & Decorating

Various methods of printing can be deployed depending on the chosen material, information to be printed, and usage environment of the final product. Examples include pad, inkjet, and laser.

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A gloved hand holds a transparent container with a light blue lid, revealing a green surgical instrument inside.

Packaging

UFP MedTech develops and manufactures sterile barrier and protective packaging in multiple formats, including pouches, trays, and clamshell packaging, using foams, films, and rigid plastics. We can also integrate packaging into a broader manufacturing program by assembling, kitting, labeling, and packaging components or devices for delivery or subsequent sterilization. This allows customers to consolidate manufacturing and packaging with a single partner.

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Cleanroom Manufacturing

UFP MedTech operates ISO Class 7 and Class 8 cleanrooms and controlled environments at select ISO 13485 certified and FDA registered facilities. These environments support medical devices, components, and packaging with defined particulate and contamination-control requirements.

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Complete Device Assembly

Complete device assembly covers multi-component assembly, kitting, and sub-assembly work, finished to sterilization-ready standards across UFP MedTech's FDA-registered facilities. Assembly work falls under the same quality system coverage as other manufacturing processes, with cleanroom assembly options available for devices requiring controlled environments. This end-to-end capability allows device manufacturers to consolidate multiple production steps with a single partner.

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Explore the materials behind our capabilities

UFP MedTech works with a wide range of materials (medical foams, thermoplastic films, rigid plastics, composites, and adhesives) selected to meet the performance, sterilization, and regulatory requirements of your device.

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Frequently Asked Questions

: UFP MedTech offers a wide range manufacturing capabilities, including compression molding, die cutting, vacuum forming, thermoplastic welding, lamination, tube finishing, packaging, cleanroom manufacturing, and complete device assembly supporting single-use and single-patient medical devices, sterile barrier packaging, and surgical drapes.
: Yes. UFP MedTech operates ISO Class 7 and Class 8 cleanrooms and controlled environments at select ISO 13485 certified and FDA registered facilities for devices, components, and packaging with defined contamination control requirements.
: Die cutting converts flat materials such as foams, films, plastics, and laminates, into precise 2D shapes using high-speed cutting tools. Compression molding shapes materials under heat and pressure into 3D formed components, such as cushioning or orthopedic parts. Both processes are used across UFP MedTech’s device and packaging solutions, often on the same product.

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Whether you need a partner for one phase of development, or all phases from concept through manufacturing, our team of experts can guide you every step of the way.