Providing Custom Turnkey Manufacturing Solutions to Convert Your Ideas to Life

Providing Custom Turnkey Manufacturing Solutions to Convert Your Ideas to Life

Custom Medical Electrodes & Tens Unit Electrode Development

For over 26 years, Pepin Manufacturing Inc. has been a leading electrode and biosensor manufacturer in the medical arena. We are a key provider of next-generation wearable technologies, including those that utilize the Internet of Things (IoT) platform.

Electrode Development — The Basics

We manufacture next-generation electrodes and sensors built to each customer’s specifications and desired application. Our team can manufacture custom electrodes and body worn sensors that can use the IoT platform, along with syncing with the customer’s software and finished medical device. We’re equipped to handle small-run functional prototyping, all the way to mass manufacturing in the millions with our roll-to-roll rotary die cutting equipment. As always, at Pepin we can incorporate semi and full automation with help from our in-house machine shop and automation engineering team.

Solving Challenges with Body-worn Sensors

Medical electrodes and body worn sensors allow for ongoing patient monitoring and/or electrical stimulation, which provide a statistical basis for a medical diagnosis and treatment. While these devices improve patient care, they also present unique challenges for device manufacturers. Specialized adhesives and purpose-built topcoats are necessary to ensure patient comfort in stick-to-skin sensors. At Pepin Manufacturing,, our product managers can source and recommend the right medical adhesive and raw materials to ensure the final product meets the performance requirements of the customer.

Some considerations we take into account when developing sensors and electrodes include:

  • Adhesion to Skin
  • Wear Time
  • Impedance Requirements
  • Environmental Factors
  • Repositionability
  • Movement that may displace the device
  • Moisture from perspiration or bathing
  • Various Skin Types

As a turn key body worn sensor and electrode manufacturer we provide:

  • Material sampling and sourcing
  • Trial runs
  • Process improvement and DFM recommendations
  • 3rd party sterilization & validation services (when required)

Our screen-printing processes utilize various conductive and dielectric inks, including silver-silver chloride and carbon, to create flexible electronics.. As specialized custom medical electrode manufacturers, we contract manufacture state-of-the-art wearable sensors built to the specifications our customers desire.

We’ve manufactured body worn sensors & electrodes for:


Measure a patient’s breathing with flexible sensors that can be used in the comfort of one’s home. Pepin has experience with sensors used for cardiac arrhythmia detection.

Heart rate

Whether you’re in the process of developing a heart rate monitor or a custom sensor used for cardiac arrhythmia detection, Pepin can provide a full suite of manufacturing solutions.

Electrical Stimulation

Pepin, being one of the market leaders in the TENS electrode manufacturing space, we can leverage our existing engineering know-how to assist with providing manufacturing solutions for various custom stimulating electrodes.

Additional Solutions

Pepin has provided design recommendations and full manufacturing solutions on electrodes and sensors used in various markets including continuous glucose monitoring (CGM), incontinence, wound healing , treatment of foot drop and stroke rehabilitation.

These sensors may be integrated into clothing, worn directly on the skin or connected to a medical device for healthcare, fitness, and medical biometrics.

We work with our customers across the entire development lifecycle, supporting their specific needs with secondary services such as design, fabrication, assembly, testing, and validation.

Our dedicated team of product managers focus on:

  • Sourcing exotic or unique materials including conductive films, conductive inks, hydrogels and custom snaps and leads to meet your application.
  • Recommending various medical-grade pressure sensitive adhesives including long-term wear, water-resistant and low-trauma solutions for both the pediatric and geriatric population.
  • Process improvement and design for manufacturability.
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Electrode Development Highlights

General Capabilities
Electrode Development
Bluetooth and Wi-Fi Enabled Sensors
Internet of Things (IoT)
Cellular and Smart Phone Connectivity
Functional Prototypes
Large Scale
Proof of Concept Prototyping
Short Run Production
Visual Prototypes (CAD)
Electrode Development
CAD (Computer Aided Design)
Material Sourcing
Material Sampling
First Article Inspection
Trial Runs
Process Improvement
3rd Party Sterilization and Validation
Conductive Screen-Printing
  • Utilization of various Ag/Ag CI Conductive inks used for monitoring
  • Printing on various substrates including PET and other films
  • Custom Artwork design Specific to customers’ needs
  • Small-Run Screen printing for Proof-of-concept and validation
Sensors capable of measuring:

  • ECG
  • Respiration
  • Heart Rate
  • Activity Level
  • Skin Temperature
  • And others
  • Product Managers Dedicated to sourcing of custom row materials
  • Access to medical-grade adhesives including low-
  • Hypo-allergenic options
  • Custom Hydrogels
  • ETO, Gamma sterilizable materials
Manufacturing Method
Flat Rule Die Cutting
Large Scale Manufacturing
Precision Rotary Die Cutting
Multi-Layer Laminating
Flexographic Printing
Conductive Screen Printing
Adhesive Backed Materials
Hydrogels (Custom and Standard)
Snap and Prewired Connections
Conductive materials
EMI/ RFI shielding materials
Films (All types)
Foams (All types) PE, Poron, ect.
Hydrocolloids/ ostomy materials
Medical grade materials
Pressure Sensitive Materials
Pressure sensitive tapes and adhesives
VHB material
Additional Services Provided
Product Design
Testing and Validation

Additional Information

Industry Focus
Material Handling
Industry Standards
ANSI – American National Standards Institute
ASTM – American Society for Testing and Materials
CE – The CE mark (officially CE marking) is a mandatory conformity mark on many products placed on the single market in the European Economic Area (EEA).
CSA – Canadian Standards Association
FDA – Food And Drug Administration
ISO – International Organization for Standardization
RoHS – Restriction Of Hazardous Substances (Compliant)
TS – Technical Specifications, used with ISO