Flambeau Medical – Capabilities

As a preferred manufacturing partner, Flambeau Medical supports the life sciences communities through every facet of their business. Whether it is producing initial prototype samples of molded components, finished device assemblies for R&D testing and clinical submissions, or producing production quantities of hand-assembled or high speed, fully automated assemblies, our engineering team works carefully with our customers to understand their product launch timeline and budgetary needs. We design a phased-manufacturing approach that meets the needs required for a successful outcome.

Product Design

Flambeau Medical’s team assists with models, prototypes, and fabrication of plastic components for injection molding and blow molding processes, while offering material recommendations. Flambeau’s experienced designers and engineers reduce your cost and improve quality by optimizing the performance and appearance of your plastic products and parts. With our premier design analysis methods and flexibility to work with virtually any design platform, Flambeau assists you in choosing the best plastic processing method for your projects.

  • In-House Tooling & Automation Services
    • Design/Build Automation and Robotic Equipment
    • Planned Tool Maintenance Connected to ERP System
    • Robotics for Molding and Assembly
    • Secondary Operations and Assembly
    • Tool Construction
    • Tool Design
  • Rapid Prototyping
    • Engineered Resin Molding
    • Prototyping

Project Management

Flambeau Medical program managers are experienced with plastic manufacturing in a wide range of markets and for a variety of customer-specific applications. All aspects of the project are continuously managed in Flambeau’s project management software, and application-specific requirements like pull testing, leak testing, and material testing are designed and developed in-house. Our customers are updated weekly on progress during project meetings with the entire Flambeau project team.

  • Design Assistance
    • CMM and Ultrasonic Panametrics
    • Color Measurement
    • Compression and Tensile Testing/Packaging
    • Force Testing
    • Mass Flow Leak Testing
    • Optical Inspection
    • Poka-yoke Assembly Fixtures
    • Pressure Decay Leak Testing
  • Medical Market Protocols
    • IQ, OQ, PQ
    • ISO 13485 Certified
  • Packaging
    • Blister Packaging
    • Cleanroom Pouch and Tray Sealing
    • Sterile Barrier Packaging
  • New Product Development
    • Product Design and Development
    • Product Design for Manufacturability
  • Product Commercialization
    • Engineering Program Management


Flambeau Medical collaborates with our Strategic Alliance Partners in the following areas:

We provide medical packaging services, including tray sealing, pouching, and sustainable packaging in a certified Class 7 cleanroom and Class 8 assembly area. Flambeau Medical excels at Just-In-Time (JIT) production using best-cost manufacturing practices and a world-class ERP system.

  • Injection Molding
    • Class 7 & 8 Certified Cleanrooms
    • 50T – 450T Injection Molding Machines
    • Insert & Over-molding
    • Micro Molding
    • Low Pressure Molding
    • Wireless, Real-time Production Monitoring
  • Vacuum Dip Molding
    • Catheter Balloons
    • Y-Connectors
    • Enema Tips
    • Nasal Cannulas
    • Cannulation (including wire reinforced)
    • High Cavitation(semi or fully automatic)
    • Multiple Material Selections
  • Decorating
    • Adhesive Labeling
    • In-Mold Labeling
    • Pad Printing
  • Cleanroom Services
    • Kitting & Sterile Barrier Packaging
  • Medical Device Assembly
    • Class ll, complex finished medical device manufacturing (manual and fully automated)
    • Heat Staking
    • Heat Stamping
    • Pad Printing
    • Ultrasonic Welding
    • RF Welding
    • Post-Mold Sonic Metal Insertion
    • Machining
    • Spin Welding
    • Adhesive Bonding
    • Ultrasonic Cleaning
    • Sterile Barrier Packaging
  • Sterilization Management Services
    • Ebeam
    • EtO
    • Gamma
  • In-House Expertise
    • Senior Science Advisor – Polymer Scientist (PhD) – Material Selection & Analysis
    • RJG Certified Scientific Master Molders
    • Lean / Six Sigma Manufacturing
  • Design & Development
  • Silicone Injection Molding
  • Extrusions
  • EMI Shielding