Cost-Efficient Scale for Complex Medical Devices
Viant Costa Rica supports high-volume interventional device programs that require molding, extrusion, and complex assembly to come together in a single, controlled environment. The site is structured to scale programs efficiently while maintaining the precision and compliance that regulated markets demand.
Operating in Costa Rica’s Zona Franca Metropolitana free trade zone, the facility delivers meaningful cost advantages for programs targeting global markets—without sacrificing quality or speed.
Thermoplastic and LSR molding, tubing extrusion, and multi-step assembly all happen on-site, keeping the full build sequence tight and responsive when designs evolve.
A dedicated NPI team has launched more than 25 programs using 3P methodology—a structured, cross-functional approach that compresses timelines and reduces launch risk. Combined with deep engineering resources and a leadership group with decades of experience, the site is equipped to manage transfers, validations, and ramp-ups as programs grow.
Costa Rica At-A-Glance
Expertise: Interventional devices, surgical technologies, bioprocessing, orthopedics, respiratory care
Known for: High-volume molding, extrusion, and complex assembly with cost advantages from free trade zone location
Certifications: ISO 13485:2016 certified, FDA registered, cGMP compliant
Environment: 395,000 sq-ft campus across 8 buildings; 123,000 sq ft cleanroom (Class 7 & 8); 47 molding presses, 4 LSR machines, 23+ assembly lines
Location:
Zona Franca Metropolitana
Barreal de Heredia, Heredia
201-3006 Costa Rica
| Core Capabilities | Our Approach | What it Means For You |
|---|---|---|
| NPI | Dedicated NPI team executing ViaLaunch™ methodology and 3P events, with cross-functional resources (PM, NPI Manager, QEs, MEs, Buyer) aligned from kickoff through production release. Over 25 successful launches and transfers. | New programs move from concept to validated production with fewer surprises, tighter timelines, and lower launch risk. |
| Program Management | Program management support grounded in EPMO and PMBOK® best practices, with Lean and Six Sigma principles embedded throughout. Viant’s team aligns to program goals, proactively manages risk, and maintains clear communication at every stage. | Clear ownership and proactive risk management from kickoff through delivery that supports audit readiness. |
| Injection Molding | Deep thermoplastics expertise across advanced materials including ABS, Nylon, PEEK, Udel, polycarbonate, and TPE. Horizontal, vertical, two-shot, and insert molding capabilities supported by an on-site tool shop with 9 certified toolmakers. | Complex molded components are produced consistently, with tooling support on-site to keep production running and respond quickly to design changes. |
| Extrusion | In-house extrusion of PVC tubing, single and dual lumen configurations, coil-shaped tubes, and wire-attached tubing. Two certified extrusion engineers with Six Sigma Black Belt training. | Tubing components are produced to spec and integrated seamlessly into downstream assembly without supplier coordination delays. |
| Complex Assembly | Precision assembly with a breadth of secondary operations including ultrasonic, and RF welding; soldering; UV curing; silicone and solvent bonding; tipping; heat shrinking; die cutting; and sewing operations. Semi-automated and manual configurations. | Finished devices come together reliably—reducing handoffs, protecting quality, and simplifying your supply chain. |
| Testing & Validation | In-process functional testing including pressure/leak, pull/peel, dye penetration, bubble, flow, and conductivity testing. Burst testing and electrical verification capabilities. | Issues are caught early in the build process, so devices perform as intended and validation documentation is ready when you need it. |
| Metrology & Inspection | Advanced metrology lab with Smart Scope CNC 500, 3D multisensor software, optical/touch/laser probe capabilities, plus dimensional, attribute, and functional inspection. | Parts meet specifications before they leave the facility—reducing downstream adjustments and supporting smoother regulatory submissions. |
| Calibration | In-house calibration lab—capabilities span dimensional, pressure, temperature, electrical, and flow measurement. | Equipment stays in spec without outside dependencies, minimizing downtime and keeping production on schedule. |
| Packaging & Sterilization | Sterile barrier packaging with inspection and shipping logistics. Partnerships with Sterigenics and STERIS for EO and radiation sterilization. Ships to US, Europe, Asia, and domestic Costa Rica markets. | Finished devices are packaged, sterilized, and delivered ready for distribution—streamlining your path to market. |
Core Capabilities & Approach & Outcomes
Finished devices come together reliably—reducing handoffs, protecting quality, and simplifying your supply chain.