MetaMedical™ Solutions Inc

Freudenberg begins construction on second Costa Rica facility

Global contract design and manufacturing partner for the medical device and biopharma industry Freudenberg Medical has commenced construction on a second manufacturing site in Costa Rica.

The new site aims to meet the growing demand for medical devices and precision components, particularly high-volume minimally invasive catheters.

Being built with a $25m investment, the new facility is strategically located near Freudenberg Medical’s existing 30,000ft² building in the Coyol Free Zone.

Planned to be operational from 2025, the new facility will focus on the assembly of minimally invasive catheters used for electrophysiology, vascular, and structural heart therapies. Initially, the site will cover 50,000ft² and include three ISO 7 cleanrooms.

Within three years of its opening, an additional 50,000ft² is planned to be added, quadrupling the manufacturing footprint of the company in the region.

During 2025, Freudenberg plans to use the existing facility as its specialised Costa Rica site for primary processing technologies, including thermoplastics moulding and extrusion for medical applications.

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Assembly operations are planned to be moved to the new facility.

Freudenberg Medical CEO Dr Mark Ostwald said: “We are proud to be one of the first global CDMO partners in Costa Rica, having established our first production facility here more than 12 years ago.

“This expansion strengthens our strategy of being close to our customers and offering them efficient solutions along the entire device lifecycle – including cost-effective manufacturing capabilities on a large scale.”

The new two-storey facility, which is expected to create 600 new jobs, will be powered by a company-owned PV solar power plant.

Freudenberg Group CTO Dr Tilman Krauch said: “This is another important step towards our goal of becoming a climate-neutral company by 2045.”

In 2023, Freudenberg opened its newly expanded facility in Galway, Ireland to meet the increasing need for its critical metal components used in minimally invasive surgery catheters.

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