The Customer
A MedTech company developing a new surgical device kit, combining injection-molded plastic components with machined metal parts. Once the design was frozen, the customer needed to move from validated design to full production, at volume, without delay.
The Challenge
With drawings finalized and geometry locked, the final product required a full set of production molds. Elos Medtech’s own mold-making workshop in Yverdon-les-Bains, Switzerland, has the expertise to build these to exacting specification, but building a program of this size in-house would have pushed the tooling phase well past the customer’s expectations.
Our Approach
To support the customer’s launch timeline, Elos combined its in-house mold-making expertise with an established network of qualified mold manufacturing partners. This enabled dozens of molds to be developed and processed in parallel, significantly accelerating the tooling phase while maintaining full control over quality and performance.
Throughout the project, Elos’s engineering and mold-making teams worked closely with suppliers to ensure every mold was manufactured to the quality requirements and technical specifications of the Yverdon site from the very first steel cut. As with all Elos manufacturing partnerships, supplier activities were managed through established quality processes and engineering oversight.
Before release into production, every mold returned to Yverdon for final adjustments, testing, and validation. Because Elos’s own engineers maintain and service these tools on site, any future modifications or repairs can be handled locally without lengthy supplier lead times.
The validated molds are then used to manufacture plastic components directly at the Yverdon facility. Parts move from injection molding into the ISO 8 clean room for assembly and packaging under controlled conditions, reducing handling, minimizing contamination risk, and supporting an efficient manufacturing flow. Metal components produced at Elos’s Montelier site are integrated into the process, resulting in a fully assembled device kit ready for sterilization and shipment.
The Outcome
Accelerated timelines. By combining internal expertise with a network of qualified mold-making partners, Elos compressed the tooling phase and helped the customer move more quickly from validated design to full-scale production.
One coordinated process. Elos managed the complete program, from mold development and validation through injection molding, assembly, packaging, and final delivery. The customer worked with a single partner throughout.
Quality without compromise. Every mold was validated in Yverdon before entering production, ensuring consistent performance and compliance with the site’s manufacturing and quality requirements.
A scalable manufacturing model. The project demonstrated how Elos can rapidly scale manufacturing capacity through trusted supplier partnerships without compromising the quality, validation, and engineering oversight that define an Elos production program.
What this means for future customers
This project demonstrates how Elos combines in-house expertise with a network of trusted manufacturing partners to accelerate complex programs while maintaining full control over quality and validation. In this case, the program was led and validated by the Yverdon site, with molds manufactured to its specific technical and quality requirements. More broadly, the same approach allows Elos sites across the network to scale capacity while applying the standards, processes, and oversight required for each individual program.
Explore our mold making capabilities here: https://elosmedtech.com/medical-polymer-solutions/mold-making-for-medical-devices/