Freudenberg Medical, a leading contract design and manufacturing organization serving the medical device and biopharmaceutical sectors, has officially opened its second production facility in Costa Rica, reinforcing its strategic footprint in the region.
Located within Coyol Free Zone, the new 50,000-square-foot of footprint facility represents a US$25 million investment, aimed at strengthening Freudenberg Medical’s nearshoring capabilities and supporting its global growth strategy. This expansion underscores the commitment of the company to delivering high-quality, scalable solutions in a region recognized for its advanced manufacturing ecosystem and skilled talent pool.
The new site is dedicated to the assembly of high-volume, minimally invasive catheters, used in electrophysiology, vascular and structural heart therapies, as well as other precision medical devices. From day one, the facility will operate three ISO Class 7 cleanrooms, with plans to double its size to 100,000 square feet footprint within three years—effectively quadrupling Freudenberg Medical’s operational footprint in Costa Rica.
“Costa Rica has become a cornerstone of our global operations over the past decade,” stated Michael McGee, CEO of Freudenberg Medical. “This new facility enhances our ability to deliver cost-effective, high-performance medical technologies at scale, while remaining close to our customers and supporting their long-term growth.”
Róger Gómez, Vice President and General Manager of Freudenberg Medical Costa Rica, added: “This expansion reflects our confidence in Costa Rica and the Coyol Free Zone as strategic enablers of innovation and operational excellence. Over the next three years, we plan to increase our team from 350 to over 900 employees. We are deeply committed to diversity and inclusion, offering equal opportunities and meaningful careers in a sector that positively impacts lives globally.”
New capabilities and optimized production
The company’s existing 30,000-square-foot facility, also located in Coyol Free Zone, will specialize in primary processing technologies, including precision molding and thermoplastic extrusion for medical and biopharma applications. Assembly operations will be transitioned to the new site to optimize production flows.
This expansion of Freudenberg Medical is supported by advanced digital technologies, including virtual reality (VR) and artificial intelligence (AI), which will be leveraged to enhance operator training, streamline production processes, and facilitate technology transfers across its vertically integrated global network. Operators will train in immersive VR environments replicating real production conditions, while AI-driven layout planning will optimize workflows based on Lean manufacturing principles.
Earlier this month, Freudenberg Medical also announced a multi-year partnership with David Schnur Associates (DSA), further expanding its global network and reinforcing its commitment to innovation and collaboration.
This milestone not only marks a significant step forward in reinforcing Coyol Free Zone as a leading destination for global MedTech investment. As the most advanced Life Sciences Park in the region, Coyol Free Zone continues to attract world-class companies by offering a robust infrastructure, specialized talent, and a collaborative ecosystem tailored to the needs of the Medical Devices industry. The expansion of Freudenberg Medical exemplifies our role in enabling innovation, accelerating growth, and strengthening the reputation of Costa Rica as a strategic hub for Smart Manufacturing and global health solutions.