Manufacturing + Assembly
SURGICAL SPONGES
Carwild Corporation is the premier private-label manufacturer of specialty surgical sponges.
Utilizing USP and pharmaceutical-grade rayon, , foam, and cotton sourced from NAFTA countries, we are committed to delivering the highest quality products with minimal concerns for our clients. Our product line includes everything from endoscopic sponges on 16” sticks to ¼” dissectors and eyespears.
We manufacture:
- Dissecting sponges
- Endoscopic sponge sticks
- Eye spears and drains
- Neurological sponges
- Packing sponges and dressings
- Surgical sponge balls
- Tonsil sponges
- X-ray detectable flat sponges
Carwild custom-manufactures and packages sponges to meet your exact specifications, available in sterile formats or bulk. We work with a wide range of materials, including cotton, rayon, polyester, gauze, non-wovens, polyvinyl acetate (PVA) and polyurethane (PU) foams, and pultrusion’s.
HYRDRASORB HYDROPHILIC URETHANE (PU) FOAM
Hydrasorb Foam Technology
High-Performance Hydrophilic Foam for Advanced Applications
Hydrasorb is a registered trademark representing a proprietary medical-grade polyurethane hydrophilic foam platform with a strong reputation for quality, consistency and performance.
Custom Foam Applications
Carwild is proud to be among the select few manufacturers with the capability to mold Hydrasorb foam into specialized shapes and components. Its unique hydrophilic properties make it highly adaptable across industries and uses:
- Medical: Wound care, medical devices, dental applications
- Packaging: Protection for sensitive electronics and specialized equipment
- Cosmetics: Precision foam applicators
Design and Manufacturing
Our experienced design and manufacturing team collaborates closely with OEMs to deliver complex hydrophilic foam solutions that meet the most demanding specifications. We are committed to building long-term, mutually beneficial partnerships through innovation, reliability and responsive service.
CERTIFICATIONS
FDA Registered Manufacturing Site
QMS ISO Certified
CERTIFICATIONS
Our IVALON brand products are made from a proprietary hydroxylated polyvinyl acetate (PVAc) foam that was developed by the pioneer of modern PVAc technology. Backed by over 40 years of trusted use in medical environments, IVALON foam delivers a unique blend of high absorbency, fast wicking and superior strength.
Its key features include:
- Soft and highly absorbent with rapid fluid wicking
- Lint-free and fiber-free for clean performance
- Exceptional tensile strength—won’t tear or shred during use
- Smooth, rounded edges for easy and comfortable insertion
- Supplied compressed for effortless placement
- Easily trimmed with scissors for custom sizing
Carwild Corporation offers collaborative product development using our PVA foam technology, helping you bring your unique designs to life with confidence and precision.
COTTON, CELLULOSE, AND RAYON
Carwild Corporation has extensive experience in working with cotton, cellulose and rayon. Through our robust network of trusted material manufacturing partners, we have the ability to engineer customer woven and non-woven fabrics, as well as coated material, designed to meet precise performance standards. These materials are then converted in-house into high-quality finished medical devices, tailored for both private-label and OEM markets.
Our Business Development Department plays a hands-on role in this process, working in close collaboration with client companies to understand their unique requirements, propose innovative solutions and guide products or develop entirely new ones, Carwild offers the expertise, flexibility, and manufacturing capabilities needed to bring their ideas to life.
PULTRUSIONS:
Carwild Corporation’s pultruded endoscopic rods are engineered for affordability and single-use convenience, offering a comparable stiffness and reduced weight over surgical steel and aluminum. Made from fiberglass-reinforced material and a custom-formulated proprietary resin, these rods are lightweight, non-conductive, and corrosion-resistant. Their non-reflective surface provides enhanced optical clarity under magnified lightering or laser-based procedures.
Carwild’s endoscopic dissectors have been successfully tested in accordance with ISO 10993-1 standards for surface devices used on breach or compromised tissue for up to 24 hours. Endoscopic devices are FDA registered , these devices are designed for reliability and safety. The rods can be machined into virtually any configuration while retaining excellent flexural strength, biocompatibility, electrical insulation, and resistance to corrosion. The versatile pultrusion process also allows for a wide range of shapes to meet demanding specifications.
MEDICAL THREAD & BRAIDED TEXTILES
Carwild is committed to strategic business development through close collaboration with our customers. We specialize in delivering braided textile solutions with unique properties and custom configurations for medical applications. Our advanced manufacturing capabilities encompass every stage of production – including braiding, spinning, twisting, stretching, reeling, dyeing, coating, spooling and packaging.
From small custom batches to large-scale production runs, we offer full design and development support along with tailored packaging and labeling services.
Medical Products:
Surgical Cords: Engineered, medical-grade strings, threads and cords
Medical Braided Tape: Soft, flat braided tapes available in various widths and lengths, our Champion Tapes are crafted from high-quality spun polyester yarns and are currently available in 1/8”, 3/16” and ¼” widths.
MEDICAL ASSEMBLY:
Carwild Corporation offers comprehensive in-house capabilities to support the production of high-quality medical assemblies. Our services include precision cutting, folding, gluing, sealing, sewing, packaging and through inspection to ensure product integrity and performance. With a workforce of over 750+ skilled employees and multi-shift operations, we are equipped to meet a wide range of customer requirements- efficiently and at scale.
Advanced Equipment and Technology:
- Automated folding Machines
- Automated Packaging Lines
- Clicker Presses
- Die Cutting Systems – sub description
Carwild Corporation provides a comprehensive range of die-cut fabrics and custom-molded foam components, tailored to meet the demands of medical applications. Our foam offerings include hydrophilic polyurethane (PU) and polyvinyl alcohol (PVA), with formulations that can be custom blended to meet your product’s specific performance requirements.
Foam Materials can be cut to size, cast into sheets or precision die-cut to exact specifications. They may also be further enhanced through adhesive application, gluing or ultrasonic welding. With production facilities in both Old Mystic, CT and the Dominican Republic, we offer flexible labor solutions and complete in-house assembly, and packaging services customized to your needs.
Our commitments to quality, compliance and performance ensure that your products are built with dependable materials and supported by trusted manufacturers.
Medical Packaging
Carwild Corporation offers a wide range of sterile and non-sterile packaging options to meet the specific requirements of medical and industrial applications. Our advanced capabilities include:
- Form-Fill-Seal packaging systems
- Rotary Medical Pouch Sealing
- Polybag heat sealing
Whether your product requires cleanroom-grade sterile packaging or efficient non-sterile solutions, Carwild is ready to deliver reliable, high-quality packaging tailored to your specifications.
Medical Sewing
Carwild Corporation offers a wide range of sterile and non-sterile packaging options to meet the specific requirements of medical and industrial applications. Our advanced capabilities include:
- Form-Fill-Seal packaging systems
- Rotary Medical Pouch Sealing
- Polybag heat sealing
Whether your product requires cleanroom-grade sterile packaging or efficient non-sterile solutions, Carwild is ready to deliver reliable, high-quality packaging tailored to your specifications.
Pad printing Technology
Carwild Corporation offers specialized expertise in medical sewing and assembly, supporting a wide range of healthcare applications. From precision hand-sewing to fully automated, computer-controlled sewing systems, we provide flexible solutions tailed to each client’s needs. Our skilled team produces a variety of sewn medical products –including neurosponges, wound dressings, arm boards, podiatric wraps, and orthopedic components – with exceptional quality and cost-efficiency.
Key Equipment and Capabilities:
- Straight stitch sewing machines
- Lock stich machines
- Multi-needle overstitch machines
- Tackers
- Sonic sewers
- Ultrasonic welders
- Slitters
- Strip cutters
- Layout tables
Ultrasonic Welding Systems
Carwild Corporation operates 20+ ultrasonic welding machines, offering both staking and continuous welding capabilities. Our team specializes in developing custom tooling and procedures to ultrasonically bond, “sew” or heat-weld materials – ideal for both woven and non-woven substrates.
We work closely with clients and trusted ultrasonic design partners to create tailored solutions that meet each project’s specific requirements. From initial design to full scale production, Carwild delivers high performance, scalable ultrasonic welding services.