Medical Product Design and Development

Estes brings medical design innovation and fabricating automation to the medical industry it’s been serving for over 30 years.

We work with top medical manufacturers to deliver precision fabricated sheet metal products that cost-effectively combine form with function. We are your innovative design partner, not just another vendor.


Contact Estes Medical Design to learn how our innovative approach will help you deliver better quality – faster with greater cost efficiency.

Medical tray design
Product Design

Design Input

Innovative Approach

We believe the best results come from collaboration. It all begins with asking the right questions and then listening closely. Once we understand exactly what you need out of a case or tray, we provide thoughtful solutions to solve your medical product design challenges.

Let's Create Something Together

Simplified Bill of Materials • Improved Sterilization • Stylish Signature looks

Estes is different than many other medical device manufacturers, which is why so many leading medical technology companies choose to work with us. The Estes difference includes:

Creative, Innovative Thinking – Estes has assembled a core group of engineers that challenge modern methods and are committed to solving problems. Our team is focused on reducing lead-times and finding cost-effective solutions for our customers.

State-of-the-Art Technology – Estes is committed to utilizing the latest equipment and lean processes to ensure that our customers get precise, high-quality, best-in-class products.

Ability to Scale – Estes employs a staff of more than 110 associates, has 65,000 square feet of manufacturing space, and features a high level of capacity-multiplying automation to provide even the largest companies with on-time fulfillment services.

Trustworthy Team – For over four decades, Estes has been committed to hiring people of high character who are focused on delivering the highest level of service to medical OEMs.

Close up of metal design

Medical Products

  • Sterilization cases and trays
  • Components and weldments for patient handling equipment
  • Panels and enclosures for diagnostic equipment
  • Pharmaceutical trays
  • Cabinetry and cabinetry components

Let us take your medical product design to the next level.

Medical Product Design Capabilities

Fabricating Services

  • Punching
  • Fiber laser cutting
  • Edge softening
  • Forming
  • Panel bending
  • Laser welding
  • Assembly

Finishing Services

  • Anodizing
  • Silk screening
  • Nylon coating
  • Electro-polishing
  • Laser etching/marking
  • Passivation
  • Painting

Case Studies

Case Study #1

A leading manufacturer of light boxes for medical imaging professionals

Client Need

The original design of a client’s steel pan used in a medical application was a three-piece, spot welded assembly that cost $29.65.

Estes Solution

To increase manufacturing efficiency, the Estes team utilized the Salvagnini forming cell. The three components were consolidated into one complex, yet more economic part with twelve bends. The redesign reduced the overall production cost to under $19 dollars and resulted in a 37% savings.


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Case Study #2

An industry leader in medical devices & orthopedic care

Client Need

Customer was developing an orthopedic case and tray delivery system that would be sold globally and would need to hold up to the harsher cleaning processes in Europe that were adversely affecting plastic and anodized aluminum products.

Estes Solution

Our designers developed an innovative custom system that was completely stainless steel, which can endure the harsher processes and offers improved sterilization.


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Case Study #3

A cardiologist and highly respected doctor

Client Need

Customer realized there was a problem when a surgeon was working in a cath lab; the lead vest that must be worn is extremely heavy and wears on the surgeon, expending energy and making surgery much more difficult. The client wanted to created an invention that would take the weight of the vest off the surgeon, while also allowing for the mobility necessary for the surgeon to be successful.

Estes Solution

Our prototype and product development team worked together to design and develop a completely custom system that used a cable and zero-gravity suspension tool to remove the weight of the lead vest and also allow surgeons the flexibility to move as needed.


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Estes is ISO 9001:2015 and ISO 13485:2016 certified.