Plexus
Wisconsin product engineering and manufacturing company serving healthcare, aerospace and industrial clients
Founded 1979 | Neenah, WI, USA | ~20,000 employees
electronicsmechanicalmanufacturingverificationregulatory
What is Plexus?
Plexus Corp. is a NASDAQ-listed company headquartered in Neenah, Wisconsin, that offers design and development, supply chain, new product introduction, manufacturing and sustaining services. Healthcare and life sciences is one of its three markets alongside aerospace and defense and industrial. Its healthcare work includes surgical equipment, imaging equipment and diagnostic instruments. The company has around 20,000 employees in total, though only part of that is healthcare.
Plexus works primarily with clients in Surgical & robotics, Diagnostics & lab devices, Aerospace, Industrial sectors. Its primary differentiator is: Engineering, NPI and sustaining services for low-to-mid volume, high-complexity medical equipment.
Plexus tech stack and services
PCB designPCB assemblyEmbedded C/C++Supply chainISO 13485 QMS
| Service area |
|---|
| Electronics & PCB Design |
| Mechanical Engineering |
| Manufacturing & Scale-up |
| Verification & Validation |
| Regulatory & QMS Support |
Plexus pricing
Short answer: Plexus uses a npi contract, manufacturing supply agreement pricing approach. Minimum engagement is not publicly disclosed; a discovery call is required.
| Engagement model | Typical range | Best for |
|---|---|---|
| Fixed project | From not disclosed | Well-defined scope |
| Manufacturing contract | Variable; depends on team size | Large programmes or team augmentation |
Plexus does not publish a public rate card. Contact them directly via their website to get project-specific pricing.
Plexus pros and cons
| Advantages | Things to consider |
|---|---|
| +Strong with complex, lower-volume capital equipment such as imaging and surgical systems | -Generalist manufacturer; healthcare competes with aerospace and industrial for capacity |
| +Offers product engineering as well as manufacturing | -Not a fit for early-stage concept work |
| +Sustaining engineering over long product lives | -Most engineering engagements lead toward a manufacturing contract |
| +Public company with transparent financial reporting |
Plexus vs alternatives
How Plexus compares to the other top Medical Device Development companies.
| Company | Best for | Key difference | Rating | Compare |
|---|---|---|---|---|
| Lemberg Solutions | Connected and smart medical devices, one engineering team. | Owns PCB design, firmware, embedded Linux, IoT backend and edge AI under one roof, so device and cloud are designed together | 4.8 | Full comparison |
| StarFish Medical | Startups needing design plus pilot manufacturing. | Medtech-only practice that can build clinical and early commercial units in its own certified clean room | 4.6 | Full comparison |
| Sunrise Labs | Electromechanical devices, fluidics and infusion. | Three decades of work on pumps, fluidics and motion-heavy medical systems where mechanics and firmware are tightly coupled | 4.5 | Full comparison |
| Velentium | Implantables and FDA cybersecurity submissions. | Combines active-implantable engineering with a dedicated device cybersecurity team that prepares FDA premarket security documentation | 4.5 | Full comparison |
| Cambridge Consultants | Novel technology with high technical risk. | Physicists, chemists and engineers working in one building on problems no off-the-shelf design can solve | 4.4 | Full comparison |
| TTP | Pharma device programs, inhalers and injectors. | Employee ownership plus long-running drug delivery and surgical device work for large pharma and medtech clients | 4.4 | Full comparison |
| Zühlke | European medtech firms modernizing device software. | A device engineering practice and a large digital practice under one owner, useful when a device program is really a platform program | 4.4 | Full comparison |
| MedAcuity | Device makers with hardware but no software team. | US-based, ISO 13485 certified team that does nothing but regulated device software | 4.3 | Full comparison |
| Key Tech | IVD instruments with consumables. | Designs the diagnostic instrument and its cartridge together, with human factors in the same studio | 4.3 | Full comparison |
| Team Consulting | Inhalers, injectors and human-factors-heavy devices. | Three decades of medical-only industrial design and human factors, especially for drug delivery | 4.3 | Full comparison |
| Minnetronix Medical | Electronic devices from design into US production. | Develops and then manufactures electronic medical devices in the same Minnesota medtech cluster | 4.3 | Full comparison |
| Planet Innovation | Diagnostics companies in Asia-Pacific and the US. | Diagnostics roots plus product and commercialization experience in Australia and the US | 4.2 | Full comparison |
| Orthogonal | SaMD and device companion apps. | Agile delivery adapted to FDA-regulated software, focused on the app and cloud side of connected devices | 4.2 | Full comparison |
| S3 Connected Health | Pharma companies adding connectivity to drug delivery. | Combines embedded wireless engineering with patient-facing apps and data platforms for pharma programs | 4.2 | Full comparison |
| Veranex | Device design plus clinical trials and reimbursement. | One contract can cover engineering, clinical studies, regulatory strategy and reimbursement | 4.2 | Full comparison |
| Sagentia Innovation | Surgical robotics and combination products. | Medical development backed by a listed science group that also runs a regulatory consultancy | 4.1 | Full comparison |
| Bluefruit Software | UK device makers outsourcing firmware and testing. | Small, employee-owned embedded team with medical devices as its largest market and a strong testing culture | 4.1 | Full comparison |
| Promenade Software | Small device makers needing software and security. | Pairs contract device software with its own medical cybersecurity tooling and information-sharing service | 4.1 | Full comparison |
| Integrated Computer Solutions (ICS) | Touchscreen user interfaces on medical devices. | Qt and embedded UI depth applied to regulated device software, including on QNX | 4.0 | Full comparison |
| Delve | User research and industrial design for medtech. | Design research and industrial design depth from two long-established US studios | 4.0 | Full comparison |
| Kaleidoscope Innovation | Enterprises already working with Infosys. | US medical design studio with access to Infosys engineering and digital capacity | 4.0 | Full comparison |
| Product Creation Studio | Pacific Northwest startups and lab instruments. | Small ISO 13485 studio that can follow its own quality system or the client's | 4.0 | Full comparison |
| Simbex | Sensor wearables and biomechanics research. | Biomechanics and sensor research background applied to wearable health devices | 3.9 | Full comparison |
| Softeq | Connected devices needing hardware plus apps. | Hardware, firmware, mobile and cloud teams in one company, with ISO 13485 in place | 3.9 | Full comparison |
| ScienceSoft | SaMD and device software on a budget. | Large, ISO 13485 certified software team with healthcare analytics and testing services | 3.9 | Full comparison |
| Tata Elxsi | Large medtech firms offshoring sustaining engineering. | Offshore scale for verification, documentation and sustaining work on existing device portfolios | 3.9 | Full comparison |
| Phillips-Medisize | Drug delivery devices needing high-volume production. | Design, molding and assembly of drug delivery devices under one global quality system | 3.9 | Full comparison |
| Jabil Healthcare | Global production capacity for cleared devices. | Global scale, supply chain and FDA-registered production for established medical device brands | 3.8 | Full comparison |
| Flex Health Solutions | Design transfer into global contract manufacturing. | Dedicated NPI center and design sites that feed directly into Flex's medical manufacturing network | 3.8 | Full comparison |
Plexus FAQ
What is Plexus?
Wisconsin product engineering and manufacturing company serving healthcare, aerospace and industrial clients
How much does Plexus charge?
Plexus uses npi contract, manufacturing supply agreement pricing. Minimum engagement is not publicly disclosed. A discovery call is required to get project-specific quotes.
What tech stack does Plexus use?
Plexus works with PCB design, PCB assembly, Embedded C/C++, Supply chain, ISO 13485 QMS. Primary industries served include Surgical & robotics, Diagnostics & lab devices, Aerospace, Industrial.
Is Plexus right for enterprise?
Complex capital equipment needing build and sustaining. ~20,000 team size. Key consideration: Generalist manufacturer; healthcare competes with aerospace and industrial for capacity.
What are the best Plexus alternatives?
The best alternatives to Plexus depend on your use case. Top options are:
- Lemberg Solutions: owns pcb design, firmware, embedded linux, iot backend and edge ai under one roof, so device and cloud are designed together
- StarFish Medical: medtech-only practice that can build clinical and early commercial units in its own certified clean room
- Sunrise Labs: three decades of work on pumps, fluidics and motion-heavy medical systems where mechanics and firmware are tightly coupled
Compare Plexus with other Medical Device Development companies
Plexus vs Lemberg Solutions Plexus vs StarFish Medical Plexus vs Sunrise Labs Plexus vs Velentium Plexus vs Cambridge Consultants Plexus vs TTP Plexus vs Zühlke Plexus vs MedAcuity Plexus vs Key Tech Plexus vs Team Consulting Plexus vs Minnetronix Medical Plexus vs Planet Innovation Plexus vs Orthogonal Plexus vs S3 Connected Health Plexus vs Veranex Plexus vs Sagentia Innovation Plexus vs Bluefruit Software Plexus vs Promenade Software Plexus vs Integrated Computer Solutions (ICS) Plexus vs Delve Plexus vs Kaleidoscope Innovation Plexus vs Product Creation Studio Plexus vs Simbex Plexus vs Softeq Plexus vs ScienceSoft Plexus vs Tata Elxsi Plexus vs Phillips-Medisize Plexus vs Jabil Healthcare Plexus vs Flex Health Solutions
Verify all details directly with Plexus before making a decision.