As healthcare products become more complex and development timelines continue to accelerate, manufacturers are under growing pressure to validate designs earlier while reducing downstream production risk. Responding to this need with greater speed, confidence and manufacturing insight, MGS, a global healthcare contract development and manufacturing organization (CDMO), has expanded its hybrid tooling capability globally following successful implementation alongside the company’s A.i.r. Platform™.

Designed to streamline the transition from early-stage prototyping methods to full-scale manufacturing, hybrid tooling delivers real injection-molded parts under production-representative conditions before customers invest in final production tooling. The approach combines aluminum prototype tooling with strategically integrated steel components in areas where tolerances, wear and material behavior are most critical to replicate key production conditions while maintaining faster development timelines. This gives healthcare innovators earlier insight into production readiness, material performance and tooling considerations while preserving the speed and flexibility needed during product development.

“Healthcare companies are under increasing pressure to move quickly while minimizing development risk,” said Shawn Krenke, Chief Technology Officer at MGS. “Hybrid tooling helps customers validate designs earlier using representative manufacturing conditions without requiring an early investment in production-scale tooling. By expanding this capability globally, we’re bringing a proven development workflow to more customers around the world.”

Traditional prototype tooling methods, including 3D printed and fully aluminum tooling, can produce sample parts quickly but often do not fully replicate final production materials, tolerances or manufacturing behavior. Full production tooling provides those conditions but can require significant upfront investment before product and tool designs are fully validated.

MGS hybrid tooling combines the agility required during early-stage product design and development with real production insights. From initial engagement to falling sample parts in as little as one month, hybrid tooling helps customers:

  • Accelerate product development timelines
  • Improve confidence in design decisions
  • Identify manufacturing considerations earlier in development
  • Reduce downstream production risks and surprises
  • Support a smoother transition into scalable manufacturing

The integration of hybrid tooling further evolves MGS’ comprehensive moldmaking portfolio, which includes Fast-Track Tooling, Design for Manufacturability (DFM) / Early Supplier Involvement (ESI) and sophisticated high-cavitation production tooling. These technologies are accessible globally, with advanced tooling facilities across North America and Europe that support companies closer to where they develop, manufacture and distribute products.

Backed by decades of experience in advanced healthcare tooling innovation, MGS supports leading Pharmaceutical, Diagnostics and MedTech companies with end-to-end solutions across Design & Development, Tooling, Automation and Manufacturing. Combining global capabilities with agile collaboration, MGS helps customers accelerate healthcare innovations that improve lives.

To learn more about MGS, visit mgsmfg.com.