Freudenberg Medical, a global contract design and manufacturing (CDMO) partner to the medical device and biopharma industry, has officially inaugurated its second production facility in Costa Rica. The new site represents a $25 million investment.
The 50,000-square-foot facility is the company’s second site in the Coyol Free Zone. It is dedicated to the assembly of high-volume minimally invasive catheters for electrophysiology, vascular and structural heart therapies, and other medical devices that require manual assembly.
Three ISO Class 7 cleanrooms are operational from day one, with plans to double the site to 100,000 square feet within the next three years — quadrupling Freudenberg Medical’s total footprint in Costa Rica.
During 2025, the company’s existing 30,000-square-foot facility nearby will specialize in primary processing technologies, including precision molding and extrusion of thermoplastics for medical and biopharma applications, while assembly operations will be consolidated at the new site.
The Costa Rica expansion is supported by advanced digital technologies. Freudenberg Medical combines Virtual Reality (VR) and Artificial Intelligence (AI) to enhance operator training, streamline production processes, and enable technology transfers across its global vertically integrated network.
Operators train in immersive VR environments that replicate the exact conditions of the production floor, ensuring standardization in critical processes and consistent quality across all sites. At the same time, AI-powered layout planning is used to model and optimize production flows following lean principles – minimizing waste, reducing costs, and involving customers early in the planning of future production lines.
