Precision You Can Trust. Capacity You Can Grow With.
Medical Device Injection Molding
From validation through full-scale production, Red Star delivers precision-molded medical components with the consistency, quality, and control your program demands.
- Precision and Repeatability
Maintain critical dimensions, tight tolerances, and consistent part quality across every production run. - Scalable Production Capacity
Support programs ranging from early production through high-volume manufacturing with horizontal and vertical presses from 10 to 250 tons. - Medical-Grade Material Expertise
Process advanced thermoplastics, including polypropylene, polycarbonate, ABS, Ixef®, PEEK, carbon-filled PEEK, and Radel®.
Insert Over Molding
Our insert over molding expertise combines metal, extrusion, and polymer components into durable, integrated medical device assemblies.
- Secure Component Integration
Mold polymers directly around cannulas, needles, metal inserts, extrusion and other components to create a reliable mechanical bond. - Reduce Secondary Operations
Eliminate adhesives and minimize manual assembly steps by integrating multiple components during the molding process. - Improve Device Performance
Produce strong, consistent assemblies designed to meet functional, dimensional, and performance requirements.
Complex Components & Assemblies
Red Star produces complex molded components and assemblies with the precision, consistency, and quality required for critical medical applications.
- Complex Part Geometries
Leverage precision medical device injection molding to create intricate features, thin walls, tight tolerances, and challenging component designs. - Design for Manufacturability
Evaluate part geometry, material selection, tooling, and processing requirements to improve manufacturability and reduce risk. - Consistent Product Quality
Apply controlled molding processes and rigorous inspection methods to maintain repeatable performance.
High-Volume Medical Device Manufacturing
Our molding capabilities, multi-cavity tooling, and automation expertise provide an efficient path to reliable, high-volume production.
- Efficient Production Scaling
Transition programs from validation into commercial manufacturing with the equipment, people, and capacity needed to grow. - Optimized Cycle Times
Refine tooling, processing parameters, and automation to improve throughput and manufacturing efficiency. - Competitive Per-Part Costs
Combine multi-cavity molds, efficient processes, and production automation to reduce costs at scale.
Mold Transfer & Production Support
Red Star helps OEMs transfer existing molds and production programs with a structured approach designed to maintain quality and supply continuity.
- Comprehensive Tool Evaluation
Inspect incoming molds to assess condition, compatibility, maintenance needs, and production readiness. - Efficient Program Transfer
Coordinate tooling, documentation, validation, and production requirements to streamline implementation. - Long-Term Manufacturing Support
Provide ongoing mold maintenance, process control, quality oversight, and scalable production throughout the program lifecycle.
Red Star specializes in overmolding for Orthopaedic instruments
Benefits of Working with Red Star
Injection and Insert Over Molding FAQ
What kinds of components can Red Star mold?
Red Star has experience molding custom device components including device handles, retention hubs, biopsy needles, drivers, drills, catheter products, and single-use procedure instruments.
Can Red Star overmold electronic and metal components?
Red Star’s precision molding capabilities apply polymers safely and securely around metal and electronic parts to form durable bonds without the need for additional adhesives.
Can Red Star optimize product designs for molding?
Our experienced engineers can assess your current device design to find opportunities for improved manufacturability while taking into consideration part geometry, device materials, and performance requirements, so you can deliver high-quality products to market faster with less risk.
How does Red Star control product quality and consistency during molding?
Our controlled molding process allows for tight tolerances and product consistency. Device validation and inspection steps help us catch inconsistencies early, so we can refine tooling and device molding for maximum reliability and efficiency.
Can Red Star use existing molds from another supplier?
When customers transfer their molding program to Red Star, we assess all existing molds and manufacturing processes to ensure a smooth transition while identifying opportunities to improve product manufacturability.
Product Expertise Built Over Decades
From orthopedic devices to vascular access components, we’ve helped OEMs bring a wide range of medical devices to market.
Tell Us About Your Device
Partner with Red Star to streamline your path from development through production.
Injection Molding & Insert Over Molding Gallery
