Custom Medical Electrodes & Tens Unit Electrode Development

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Electrode Development Process
Electrode Development Process
For over 25 years, Pepin Manufacturing Inc. has been a leading electrode and biosensor manufacturer for the cosmetic, electrotherapy and medical industries. We are a top provider of next-generation wearable technologies, including those that utilize the Internet of Things (IoT).

Electrode Development — The Basics

We design and 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 capable of Bluetooth and Wi-Fi connectivity. 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 to meet your volume needs.

As a single source medical sensor and electrode manufacturer we provide

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

We provide a screen-printing process that can utilize various conductive and dielectric inks to create flexible electronics, including silver-silver chloride and carbon. As specialized custom medical electrode manufacturers, we design and manufacture state-of-the-art wearable sensors built to the specifications our customers desire.

We’ve manufactured sensors that measure:

  • ECG
  • Respiration
  • Heart rate
  • Temperature
  • Activity levels
  • Much more

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 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 for both pediatric and geriatric population.

All of our products can be manufactured under your private label, making it simple for our customers to have a successful product launch.

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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

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