Manufacturing & Services
Electrotherapy Electrode Solutions by Pepin Manufacturing
At Pepin Manufacturing, Inc. (PMI), we specialize in the manufacturing and services required to produce high-quality electrotherapy electrodes for medical and therapeutic applications. With decades of experience in contract manufacturing, we offer scalable, consistent, and cost-effective solutions to support OEMs, private label brands, and healthcare product distributors.
Our approach combines advanced production technologies with precision converting and strict quality assurance, ensuring that every electrode we produce performs reliably and safely in the field. By aligning technical expertise with customer goals, we offer manufacturing solutions that are both innovative and grounded in practicality.
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About Electrotherapy Electrode Manufacturing
For over 30 years, Pepin Manufacturing, Inc. has been a leading manufacturer of electrotherapy electrodes under the Advantrode trademark name.
Our electrodes are best in class thanks to their:
- 100% uniform current dispersion
- Improved reusability
- Ultra-low impedance
Our fully automated processes enable us to continue manufacturing USA-made electrotherapy electrodes at competitive prices, offering a wide variety of TENS units, leadwires and accessories.
End-to-End Manufacturing and Services for Electrotherapy Electrodes
We provide comprehensive manufacturing and services that cover the entire lifecycle of electrotherapy electrode production. From sourcing raw materials to final packaging, Pepin Manufacturing operates as a single-source partner for high-volume, private-label, and specialty electrode products. Our collaborative process includes thorough consultation, design adaptation, and scalable mass production.
Our capabilities include:
- Roll-to-roll electrode fabrication
- Multi-layer lamination
- Precision rotary die cutting
- Custom lead wire attachment
- Hydrogel placement (excluding hydrogel formulation)
- Printing and branding on electrode backings
- Packaging, kitting, and assembly
- In-line inspection and automated defect detection
- Flexible pack-out options for clinical or retail use
Whether you’re seeking full production support or specific contract manufacturing segments, our solutions are tailored to align with your operational needs and product goals. We help companies reduce costs, improve turnaround time, and maintain product integrity from batch to batch.
High-Performance Materials and Layer Integration
Electrotherapy electrodes are only as effective as the materials and processes behind them. That’s why our manufacturing and services place a heavy emphasis on quality material sourcing and integration. We focus on establishing consistency in material properties to ensure electrical efficiency, patient comfort, and longevity.
We work with a variety of electrode component materials, including:
- Conductive films and foils
- Carbon-based substrates
- Medical-grade nonwovens and foams
- PET liners and non-stick release layers
- Adhesive and hydrogel-compatible layers
- Specialized insulation and protective barriers
Using multi-layer lamination, we assemble these components with precise alignment and consistent thickness to meet your specific conductivity and durability requirements. Every product is built for reliable skin contact, even signal transmission, and comfortable use. Our engineers evaluate each configuration to maintain compatibility with device parameters and patient outcomes.
Precision Converting for Electrotherapy Products
Our rotary die cutting and converting operations enable high-speed production of electrodes with tight tolerances. This ensures uniform sizing, pad shape, and adhesive performance across large production runs. As part of our manufacturing and services, we provide customization options for shape, size, lead-out design, and branded labeling to differentiate your product in the market.
Whether you’re producing TENS, EMS, IFC, or other electrotherapy formats, we can scale your product without sacrificing performance or quality. With decades of experience in converting processes, we continually invest in new tooling and automation to optimize yield and reduce waste.
Customization and Private Label Capabilities
Pepin Manufacturing supports OEMs and private-label clients by offering custom branding and packaging services. As part of our manufacturing and services, we can apply client-specific artwork, logos, and product instructions directly onto the electrode backings or packaging. Our design and production teams work closely with clients to create packaging that complies with regulatory guidelines and enhances brand visibility.
Private label capabilities include:
- Custom print layouts
- Branded packaging sleeves or pouches
- Instructional inserts or product guides
- Custom pack-out configurations
- Variable data printing and barcoding
- Clinical kit and retail multipack options
Our goal is to help you launch and distribute electrotherapy electrodes under your brand with minimal lead times and full supply chain confidence. We handle both small-scale test runs and high-volume national rollouts with equal precision.
AdvanTrode® Elite
Ultra-high performance electrodes with a uniquely applied conductive pure silver layering system and pure copper lead wires with dispersive lug heads to help achieve best-in-class electrical dispersion and conductivity to maximize patient comfort.
AdvanTrode® Essential
General use electrodes combine quality with value. These cost-effective electrodes provide comfort and maximum reusability without sacrificing quality.
Accessories
Pepin offers electrotherapy accessories and equipment designed for therapeutic uses. Products include lead wires and batteries for TENS units and pain-relieving gel used to equip, maintain and supplement pain-relieving technology.
Quality Assurance and Regulatory Standards
Our manufacturing and services are guided by rigorous quality protocols and compliance with internationally recognized standards. All electrotherapy electrode production is managed with documentation and control systems that support traceability, repeatability, and process validation.
We align with key quality and safety standards, including:
- ANSI and ASTM specifications
- RoHS and CE directives
- CSA and TS requirements
- Cleanroom handling procedures (as required)
- Lot traceability and documented batch records
By maintaining a high standard of quality control at every production stage, we ensure that your product meets both clinical performance demands and market regulations. Our in-house quality team performs routine audits, tests, and process verifications to safeguard every shipment.
Scalable Production for Growing Demand
Our production facility is optimized for high-volume manufacturing, allowing us to support growth without compromising delivery times or product integrity. Clients turn to Pepin Manufacturing when they need a manufacturing and services partner capable of adapting to increased demand, seasonal fluctuations, or new market opportunities.
With multiple converting lines, robust material sourcing partnerships, and flexible production scheduling, we’re built for scalability and dependability. From regional distributors to global healthcare brands, we provide the infrastructure and responsiveness needed for fast-moving markets.
We also offer demand forecasting support, blanket order fulfillment, and just-in-time delivery services to help you manage inventory efficiently and stay responsive to customer needs.
Partner With the Right Electrotherapy Manufacturer
Choosing the right partner for your electrotherapy product line means more than just outsourcing production—it means aligning with a manufacturer who understands your needs and can deliver results. Pepin Manufacturing offers a true partnership through:
- Transparent communication throughout your project
- Full confidentiality and intellectual property protection
- On-time production and delivery
- Technical expertise in electrode application and usability
Our clients value our ability to streamline their manufacturing operations and bring consistent products to market efficiently. We offer both standardized and custom solutions designed to meet diverse business goals.
Industries and Applications We Serve
The electrotherapy electrodes we manufacture are used across a wide range of medical and therapeutic applications, including:
- Pain management (e.g., TENS units)
- Muscle stimulation (e.g., EMS devices)
- Rehabilitation therapy (e.g., NMES systems)
- Athletic training and recovery
- Chiropractic and physical therapy clinics
- Consumer wellness and fitness brands
- Post-operative recovery solutions
With extensive experience across these fields, our manufacturing and services are trusted by leading OEMs, distributors, and private-label brands worldwide. Our flexible capabilities make us an ideal partner for both clinical and consumer-facing applications.
Start Your Next Electrotherapy Project With Us
At Pepin Manufacturing, we’re committed to delivering excellence in every electrode we produce. Our comprehensive manufacturing and services provide the foundation for long-lasting, high-performance electrotherapy products that meet both clinical and commercial expectations.
Contact us today online or by phone at 651.345.5655 to learn more about our capabilities and how we can support your next electrotherapy electrode production run.