Scaling a Wearable Medical Device from Startup to Market

A Michigan-based medical startup developing a wearable pain-tracking device sought a manufacturing partner capable of supporting early-stage development through scalable production. With secured federal and state grant funding, the company required tooling, advanced joining capabilities, and full contract manufacturing support to bring the product to market efficiently.

Pliant Medical engaged in the project following an introduction at an industry trade show, quickly assembling a cross-functional engineering team to support design, tooling, and production planning. Our team developed production tooling, injection molded key components, and implemented laser welding processes to assemble internal and external product features.

Beyond component manufacturing, Pliant Medical was selected as the contract manufacturer for assembly and packaging—providing an end-to-end solution aligned with the customer’s commercialization goals.

Initial production is underway, with the first 5,000 sellable units scheduled for delivery in the fourth quarter. The customer’s growth projections indicate increasing monthly demand over the next two years, supported by scalable manufacturing processes established during early development.

This program highlights Pliant Medical’s ability to partner with emerging medical innovators—supporting rapid development, advanced joining technologies, and a clear path from concept to production.