Exo-s

Exo-s is a leading provider of medical injection molding, product design, and contract manufacturing services, supporting OEMs of all sizes with high-precision plastic components from concept through full-scale production. With expertise in injection molding, insert and overmolding, co- and bi-injection molding, 3D printing, and automated assembly, Exo-s delivers engineered plastic solutions for the highly regulated medical industry. Our team partners with OEMs developing diagnostic consumables, wearable medical devices, laboratory supplies, and surgical instruments, ensuring every product meets strict performance, quality, and regulatory requirements. Headquartered in Sherbrooke, Québec, Canada, Exo-s is ISO 13485 certified and operates a 4,000 ft² ISO Class 8 cleanroom dedicated to medical injection molding and assembly. This controlled environment enables us to manufacture high-quality medical components with the consistency and traceability required for today’s healthcare applications.

Expertise in plastic injection molding for medical devices

The team at Exo-s brings deep technical expertise in medical injection molding and the design of efficiently moldable plastic components. We collaborate closely with OEMs to develop complex, high-performance parts used across the medical industry. Our experience includes applications such as wearable cardiac monitoring devices, instrument guides for robotically-assisted surgeries, radial haemostasis compression bands, consumable filters for environmental microbial testing, specialized PCR tubes for diagnostic workflows, and bacteria optical detection lid and tray components.

By acting as an extension of your engineering and manufacturing teams, we tailor our approach to each project’s unique requirements. Whether supporting early-stage product development or scaling an established device, Exo-s ensures that every component is optimized for manufacturability, quality, and cost efficiency.

ISO Class 8 cleanroom for medical molding, assembly, and packaging

Exo-s operates a dedicated ISO Class 8 cleanroom designed specifically for the injection molding and assembly of medical plastic components. This controlled manufacturing environment supports the stringent cleanliness and contamination requirements associated with diagnostic, laboratory, and single-use medical devices.

Our cleanroom capabilities enable us to produce components that meet the highest quality standards while maintaining process control and repeatability. From molding to secondary assembly, we ensure that every step of production aligns with regulatory expectations and customer specifications, reducing risk and improving overall product reliability.

Design for manufacturability (DFM) in medical plastics

Our design for manufacturability (DFM) expertise helps OEMs reduce production risk, optimize part performance, and accelerate time to market. By engaging early in the product development process, Exo-s identifies opportunities to simplify geometries, improve moldability, optimize cycle times, and minimize downstream challenges. We are vertically-integrated with design and engineering services to perform Mold Flow Analysis (MFA) to minimize manufacturing challenges such as sink, warp, and air traps. We work collaboratively with product development teams to refine designs and optimize processes for injection molding, overmolding, and assembly, ensuring that parts not only meet functional requirements but are also scalable for high-volume production. This proactive approach helps prevent costly redesigns, reduces tooling iterations, and improves overall manufacturing efficiency.

End-to-end medical injection molding, assembly & secondary ops

Exo-s leverages a range of advanced manufacturing technologies to deliver high-quality plastic components at scale. Our capabilities include precision injection molding, insert and overmolding, co- and bi-injection molding, and additive manufacturing (3D printing) for prototyping and design validation.

Following molding, Exo-s integrates automation, robotic, and in-line inspection systems to streamline production, improve consistency, and reduce variability. We also offer a wide range of secondary operations, including plastic welding, laser engraving, vision inspection systems, leak testing, and both in-line and off-line quality inspection. These integrated capabilities help optimize total production costs while reducing supply chain complexity by minimizing the need for multiple vendors. These capabilities are especially critical for medical applications requiring tight tolerances, repeatability, and scalable production. By combining advanced processing with automation, Exo-s ensures efficient, reliable manufacturing and inspection from prototype through commercialization.

North American medical manufacturing & supply chain support

With our medical manufacturing facility, located in Saint-Damien, Québec, Canada, Exo-s provides flexible, scalable production solutions for OEMs. Our 68,000ft2 specialized designated medical manufacturing footprint allows us to support the stringent requirements of medical injection molding, from controlled production environments to high-quality part assembly.

This focused model allows us to align closely with customer needs, whether the goal is reducing lead times, mitigating risk, nearshoring, or improving cost efficiency. We ensure consistent quality, streamlined communication, and reliable project execution across all production volumes and levels of complexity.

Proven execution in designing and manufacturing medical plastics

For over 50 years, Exo-s has delivered reliable manufacturing solutions for highly regulated industries, building a strong reputation in medical plastics manufacturing. With a team of more than 900 employees across five global locations, we bring together vertically-integrated engineering, tooling design and management, and production capabilities to support projects of all sizes.

We have partnered with a wide range of customers, from innovative startups to globally recognized OEMs, helping bring complex medical devices to market. Our focus is on long-term partnership, providing the technical support and manufacturing capabilities needed to ensure success at every stage of the product lifecycle.

Are you developing a medical device that requires precision injection molded components? Whether you are in early design or preparing for full-scale production, the Exo-s team is ready to help. Please use the form below to send us your business enquiry and start the conversation.

Press Releases

Exo-s Expands Capacity for the Future of Medical Manufacturing

White Papers

Case Study – From Design to Analysis: A New Era of Electrocardiograms with Icentia and Exo-S