Production Capabilities

Flambeau Medical is your solution for outsourcing components, sub-assemblies and complete products for the healthcare industry. Our core competencies in injection molding and blow molding – along with decorating, assembling, packaging and project management – make it possible for us to deliver fully packaged finished goods, ready for sale. What sets us apart from other plastic manufacturers is our dedication to transparency, keeping you up to date through the development and production of your product.

Molds, Tooling and Automation

Flambeau has two tool rooms (Wisconsin and Arizona) capable to build and maintain both injection and blow mold tools. Our shops have more than 40 years of experience in building and maintaining all types of tooling, from quick aluminum prototype and pilot production molds to Class 101 tools for high volume precision injection and blow molding. Close tolerance tooling and fixtures for molded medical components are produced using state-of-the-art CNC Machining, Wire EDM, and Sinker EDM equipment. We also have partners in Asia and Europe to support low-cost tooling options, when time is not a factor.

Our automation department has a full range of capabilities from simple fixtures to complex work centers to drill, tap, cut, weld, assemble and test components and products. Barcoding can be integrated into the work center or as a stand-alone system in compliance with APQP and manufacturing process instructions. Flambeau Technologies Tool Group will design and build discrete equipment for product validation, functional testing, and destructive testing.

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Packaging has been a core competency of Flambeau for decades. We offer a full range of disposable and sustainable packaging solutions, including stock cases; totes and trays for cardio, orthopedic, spinal, in vivo and surgical components, instruments and devices. Our custom packaging solutions can be configured for your specific application.

For additional information, please visit our packaging division website at

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Injection Molding

Throughout the corporation, Flambeau has more than 175 injection molding machines ranging in clamping force from 30 to 1,775 Tons. Our machines are meticulously maintained with an ERP integrated preventative maintenance system to ensure maximum performance. We operate hydraulic, electric, and hybrid presses with robotic systems for part removal, trimming, and assembly. Our Class 8 molding environment uses state of the art electric presses. We are experienced in the full spectrum of molding materials including PEEK, PVC, Ultem™, polyesters, POM, PPS, PPO, PES, PAS, PC, nylons, TPE, TPU, olefins and other commodity resins.

Ultem is a trademark of SABIC.

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Flambeau offers a variety of decorating options for your molded components or finished product.

  • Pad printing
  • Hot stamping
  • Custom painting
  • IMD (in-mold decorating) for injection molding
  • IML (in-mold labeling) for blow molding
  • Silk screening
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Blow Molding

Corporate wide, we have more than 50 blow molding machines ranging in shot capacity from 1 to 50 lbs. We operate both continuous extrusion and intermittent extrusion equipment. Our machines are meticulously maintained with an ERP integrated preventative maintenance system to ensure maximum performance. For medical applications, we have draped presses and portable clean rooms to provide a clean molding environment for part production. We are experienced with a wide range of blow molding materials, including HDPE, PP, ABS, PVC, PPO, polyester, TPE, TPU and nylons.

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New Product Development

We can assist with developing concepts/ideas into products using our support teams providing expertise in industrial design, part design, and design for manufacture as it relates to repeatable processing in a variety of manufacturing methods. We have experience with predicate devices in the industry and best-in-class methods of manufacturing and designing to protect or strengthen intellectual property.

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Medical Device Assembly

In order to manage the ever-increasing regulatory requirements placed on medical products, many OEMs seek single source providers in efforts to consolidate their supply base. Flambeau Medical is your single source provider, not only for manufacturing components, but for assembling the equipment and packaging it. We understand the need for fully qualified processes as soon as proof-of-concept prototypes are approved.

Our creative approach to assembly and automation results not only in higher levels of statistical quality, but also smaller batches and lower costs. We develop systems scalable and flexible enough to work with rapidly changing demands. Our modular approach to automation and our in-house design and development teams understand the rigorous demands and functional requirements for high volume/high speed assembly.

Flambeau serves as a Tier 1 supplier by managing the entire product supply chain for you. Our quality management system is focused on safety, reliability, compliance and documentation, regardless of the role we play in the supply chain continuum. The same regulatory support is provided whether you are looking for single components, full assemblies or complete pack-out and distribution.

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Product Commercialization

Flambeau also has resources available to help with product commercialization. With access to U.S., European, and Asian markets, we can provide product testing and submission of clinical data for CE marking, 510k approval, or even PMA submissions. We are also closely linked to other valuable resources, including clinical research organizations and several large distribution channels, both in the U.S. and abroad. If we do not have certain resources you are looking for, we will work together to find the solution.

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