Electrode Manufacturing Solutions
Custom Electrode Development Solutions for Medical, Research, and Commercial Applications
At Pepin Manufacturing, Inc. (PMI), we specialize in comprehensive electrode development services designed to support the most rigorous applications in healthcare, diagnostics, wearable technology, and scientific research. As a trusted U.S.-based contract manufacturer with an ISO-13485-certified facility, we bring decades of experience, advanced material science, and precise manufacturing techniques together to create industry-leading electrode solutions.
From hydrogel selection to fully finished, ready-to-use electrodes, our end-to-end electrode development services deliver the innovation, reliability, and customization our customers need to bring cutting-edge products to life.
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What Is Electrode Development?
Electrode development is the process of designing, formulating, manufacturing, and assembling electrodes tailored for specific biomedical, industrial, or research applications. This includes selecting and engineering the conductive medium (e.g., hydrogels or foams), pairing it with appropriate backing and adhesive materials, and producing a final product that meets exact performance, skin compatibility, and regulatory requirements.
At PMI, our electrode development process covers every step, from material formulation through to full-scale manufacturing and packaging, making us a true one-stop shop for companies developing diagnostic, therapeutic, and monitoring technologies.
Our expertise encompasses:
- Hydrogel and adhesive selection
- Die cutting, laminating, and slitting
- Skin-safe adhesive selection
- Electrode assembly and packaging
- Custom printing and branding
We have the infrastructure and expertise to help your electrode project quickly and cost-effectively.
Benefits of PMI’s Electrode Development Services
When you partner with PMI for electrode development, you benefit from our vertically integrated capabilities, engineering expertise, and commitment to quality. Our solutions are designed to meet exact specifications, optimize patient comfort, and perform consistently in both clinical and consumer environments.
Advantages Include:
- End-to-End Support: We handle every step, from material sourcing and prototyping to regulatory-compliant production and packaging.
- Customized Performance: Tailored formulations and constructions ensure your electrode meets specific impedance, adhesion, wear time, and signal transmission needs.
- Skin-Safe Materials: All components are selected for biocompatibility, minimizing irritation for long-term wear or sensitive applications.
- Rapid Prototyping: Our in-house lab can quickly develop and iterate prototypes, reducing time to market.
- Advanced Manufacturing: We use precise coating, die cutting, and laminating techniques to ensure consistent electrode geometry and performance.
Regulatory Confidence: With ISO-13485 certification and FDA registration, we support your quality and documentation needs for regulated markets.
Industries and Applications We Support With Electrode Development
Our electrode development services are trusted by companies in a wide range of sectors that require reliable, high-performing electrodes for professional, commercial, and consumer use. Whether you’re launching a new health tech product or producing diagnostic patches at scale, PMI provides the flexibility and expertise needed for high-quality results.
Medical & Healthcare
- TENS & EMS electrodes for pain relief and physical therapy
- Cardiac monitoring electrodes (ECG/EKG)
- Neurostimulation electrodes for research and therapeutic use
- Bio-signal recording and patient monitoring sensors
- Skin-mounted electrodes for wearable medical devices
Diagnostics & Life Sciences
- Electrochemical diagnostic strips
- Single-use electrodes for rapid testing or lab work
- Research-grade hydrogel electrodes
- Skin-adhesive electrodes for experimental data collection
Consumer & Wearable Tech
- Fitness and health tracking electrodes
- Custom-shaped electrodes for discreet wearables
- Brand-labeled electrodes for private-label health tech companies
- Reusable and long-wear hydrogel patches for smart devices
We understand the critical role electrodes play in real-time monitoring, therapy, and diagnostics, and we tailor every aspect of development to align with your product’s end-use requirements.
Integrated Capabilities for Seamless Electrode Production
At PMI, electrode development is tightly integrated with a broad range of converting and assembly services. This allows us to manage complex projects in-house, reduce lead times, and eliminate the risk of quality degradation from multi-vendor coordination.
Supporting Capabilities:
- Hydrogel Formulation & Casting: In-house formulation and precision casting of custom hydrogels with tunable conductivity and adhesion.
- Precision Die Cutting: Accurate cutting of conductive and adhesive layers to match electrode shapes, including medical and consumer-ready designs.
- Multi-Layer Lamination: Combining substrates such as foils, conductive textiles, adhesives, and hydrogels into functional layered electrodes.
- Printing & Branding: Add logos, instructional graphics, or lot tracking directly onto electrode backings or pouches.
- Contract Packaging & Assembly: Turnkey fulfillment, including electrode packaging, sterilization prep, and kitting in sealed pouches or multi-pack formats.
With these in-house capabilities, we minimize production delays, ensure end-to-end quality, and help you launch with confidence.
Quality and Compliance in Electrode Development
As a long-time contract manufacturing partner in the medical and healthtech industries, PMI is fully equipped to meet the highest quality and compliance standards. Our electrode development process is supported by a robust quality management system, validated processes, and strict material traceability.
Quality & Regulatory Credentials:
- ISO 13485:2016-certified quality system
- FDA-registered contract manufacturing facility
- Good Manufacturing Practice (GMP) protocols
- Full traceability from raw material to final product
- Batch documentation and testing to meet regulatory submissions
We work closely with your regulatory and quality teams to support 510(k) submissions, CE markings, and other market-specific compliance needs.
Customization at Every Level
No two electrodes are alike, and that’s why customization is at the heart of our electrode development services. Our engineers collaborate with your team to design electrodes that meet your specific design, functionality, and performance criteria.
Custom Options Include:
- Shape and size customization for application-specific fit
- Hydrogel thickness and conductivity tuning
- Adhesive properties for short-term, long-wear, or reusable use
- Connector compatibility, including snap, tab, or custom interfaces
- Backing materials (foam, fabric, film) based on application needs
- Custom printing and packaging for brand consistency
Our agile development process and flexible production lines make it easy to test new ideas, iterate quickly, and scale with confidence.
Why Choose PMI for Electrode Development?
Pepin Manufacturing stands out as a leader in electrode development by combining technical excellence with a deep understanding of customer needs. We provide the speed, support, and scalability necessary to bring innovative electrode products to market, on time and on spec.
Why Clients Choose PMI:
- Decades of industry experience in electrode and adhesive product development
- Fully integrated manufacturing from hydrogel casting to final packaging
- Responsive engineering support and collaborative design process
- In-house quality, regulatory, and documentation support
- Proven track record serving global medical, diagnostic, and consumer brands
We don’t just make electrodes—we help you build smarter, safer, and more effective devices.
Get Started With Electrode Development Services Today
Ready to take your concept from idea to finished electrode product? Partner with Pepin Manufacturing, Inc. for industry-leading electrode development services. Contact our team today to start a conversation, request a quote, or schedule a consultation with our materials and engineering experts.