Freudenberg Medical expands in Costa Rica with $25M Facility

Freudenberg Medical opens new Costa Rican facility: ©Freudenberg Medical

Freudenberg Medical, a global contract design and manufacturing partner for the medical device and biopharma industries, has inaugurated a new $25 million production facility in Costa Rica, underscoring the country’s role as a fast-growing hub for MedTech near-shoring.

The new site, located in the Coyol Free Zone, is the company’s second facility in the country and will focus on the assembly of high-volume minimally invasive catheters. These devices are used in electrophysiology, vascular and structural heart therapies, as well as other treatments requiring precision manual assembly.

“This new facility represents a significant step in our growth strategy,” said Michael McGee, CEO of Freudenberg Medical, in a statement. “Costa Rica has become a cornerstone of our global operations over the past decade. With this expansion, we can deliver high-quality, cost-effective medical technology solutions on a large scale, while staying close to our customers and supporting their long-term growth.”

The 50,000-square-foot plant opened with three ISO Class 7 cleanrooms already in operation. Freudenberg Medical plans to double the site to 100,000 square feet within three years, quadrupling its overall manufacturing footprint in Costa Rica.

The company currently employs about 350 people in Costa Rica. That number is expected to grow to more than 900 over the next three years, according to Róger Gómez, vice president and general manager of Freudenberg Medical Costa Rica.

“Freudenberg Medical’s confidence in Costa Rica is evident in this investment,” Gómez said. “We are committed to diversity and inclusion, offering equal opportunities while providing meaningful careers in a growing industry that improves lives worldwide.”

Freudenberg’s existing 30,000-square-foot facility, also in the Coyol Free Zone, will specialize in primary processing technologies such as precision molding and extrusion of thermoplastics for medical and biopharma applications. Assembly operations will be shifted to the new site.

Costa Rica’s life sciences sector has grown rapidly over the past 15 years. More than 58,000 people are currently employed in the medical device industry, and exports exceeded $8.7 billion in 2024, according to CINDE, the Costa Rican Investment Promotion Agency.

“These figures reflect not only the trust that companies like Freudenberg place in our ecosystem, but also the ability of Costa Rican talent to drive complex advanced manufacturing processes with cutting-edge technologies such as artificial intelligence and virtual reality,” said Marianela Urgellés, CINDE’s managing director. “We remain committed to supporting investments that consolidate Costa Rica as a strategic partner for innovation and global health.”

The facility also highlights the company’s adoption of advanced technologies to improve efficiency and standardization. Freudenberg Medical is deploying Virtual Reality and Artificial Intelligence tools to support operator training and optimize production flows.

Operators train in immersive VR environments that mirror real production conditions, helping to ensure consistent quality and process standardization across global facilities. AI-powered planning is also being applied to model lean production layouts, minimize waste and costs, and involve customers early in planning for new product lines.

“With VR and AI, we are building the factory of the future here in Costa Rica,” McGee said. “This approach strengthens transparency, collaboration, and trust with our customers and ultimately benefits patients who rely on the therapies our customers provide.”

Freudenberg Medical employs more than 2,900 people worldwide and operates 12 manufacturing sites in key MedTech hubs. The company provides vertically integrated capabilities ranging from complex minimally invasive catheter systems to molding, extrusion, coatings and components for smart medical devices.