Fully Integrated. Carefully Controlled. Ready for What’s Next.

Medical Device Assembly

Red Star brings components together through controlled assembly processes designed to deliver consistent quality, reliable performance, and production-ready medical devices.

Simplify Your Supply Chain
Consolidate component manufacturing, assembly, and secondary operations with one accountable manufacturing partner.
Maintain Assembly Consistency
Follow documented processes and controlled work instructions to support repeatable fit, function, and device performance.
Scale with Confidence
Transition efficiently from initial production to higher volumes with flexible labor, equipment, and automation strategies.

Ultrasonic & Spin Welding

Our precision welding capabilities create strong, consistent bonds for medical device components without adhesives or additional fasteners.

Create Reliable Assemblies
Produce durable bonds engineered using in-process controls to meet the functional and performance requirements of your device.
Reduce Components and Complexity
Join molded parts directly to minimize adhesives, mechanical fasteners, and unnecessary medical device assembly steps.
Improve Production Efficiency
Controlled welding processes deliver consistent cycle times, repeatable bond quality, and scalable output.

Cannula & Needle Assembly

Red Star provides specialized medical device assembly and finishing for cannula, needle, and hub components used in demanding medical applications.

Precision Cannula Flaring
Form secure mechanical features that help retain cannula and needle components within molded hubs and assemblies.
Controlled Component Integration
Assemble cannula, hubs, handles, and related components to defined dimensional and performance requirements.
Reliable Device Performance
Verify critical assembly characteristics to support proper alignment, secure retention, and consistent function.

Laser Marking

Red Star provides precise, permanent laser marking that supports product identification, traceability, and consistent presentation.

Permanent Product Identification
Apply clear, durable part numbers, lot information, measurement indicators, and other required markings.
Improved Traceability
Support identification and tracking requirements throughout manufacturing and the product lifecycle.
Consistent Product Marking
Controlled laser marking delivers repeatable placement, clarity, and legibility across production quantities.

Passivation & Automated Cleaning

Our in-house passivation and fully automated Elma clean line prepare medical components for assembly, packaging, and subsequent validated production processes.

Enhance Corrosion Resistance
Passivation removes manufacturing contaminants and supports the protective surface condition of stainless-steel components.
Deliver Consistent Cleanliness
The automated Elma clean line provides controlled, repeatable cleaning while minimizing variability associated with manual processes.
Prepare Components for the Next Step
Receive clean, production-ready components prepared for assembly, sterile packaging, or integration into your medical device.

Benefits of Working with Red Star

Expert Craftsmanship

We’ve spent over 25 years manufacturing the latest medical device innovations. Tell us about your device, and we’ll find the right solution for you.

End-to-End Manufacturing

Red Star’s vertically integrated manufacturing services help you deliver high-quality medical devices to the providers and patients that need them.

Dedicated to Excellence

Every product we manufacture undergoes rigorous validation and testing to ensure it meets the highest standards of quality and reliability.

Medical Device Assembly FAQ

Red Star makes it easy to transfer your device manufacturing program from your old supplier to our versatile, US-based manufacturing facility.

The engineers at Red Star are experts in design for manufacturability (DFM) and can assess your product for optimization opportunities that accelerate production without compromising product quality.

By bringing product design, development, and manufacturing under one roof, Red Star helps reduce supply chain complexity. Using laser marking, we ensure all required markings are compliant, clear, and durable for easy tracking throughout the product lifecycle.

Red Star’s in-house precision tooling capabilities allow for custom-engineered tooling that meets tight tolerances, materials needs, and complex component geometry needs. Our flexible molding capabilities include insert over molding, injection molding, and multicavity molds.

We offer sterile packaging in Class 7/8 cleanrooms with controlled processes that reduce contamination risk and validate the strength and integrity of seals, pouches, and procedure kits.