I visited Insulet headquarters in Acton, MA to get a glimpse at where Omnipod is manufactured and how it has evolved over time. Stepping inside Insulet’s headquarters immediately reveals a side of the Omnipod most users never get to see. Beyond the familiar, compact tubeless device is an entire ecosystem of engineering, testing, and innovation working behind the scenes to make it reliable every single day. The facility brings together specialists from multiple disciplines—mechanical engineering, materials science, electronics, and quality assurance—all focused on producing a pump that quietly supports life with diabetes.

The journey begins in Insulet’s Research & Development Lab, where every version of the Omnipod originates. Here, prototypes are built, stress-tested, torn apart, and reimagined. Early concepts sit beside modern designs, showing the evolution from bulkier models to the sleek devices used today. The space is filled with test rigs, advanced imaging tools, and stations dedicated to refining even the smallest components. Every improvement—better adhesion, smoother insertion, more accurate delivery—starts with the experiments happening in this room.

A closer look at the Pod’s inner workings shows just how much engineering is packed into such a small form factor. The insulin reservoir, automated insertion mechanism, micro-electronics, and waterproof housing operate in harmony to deliver insulin consistently and safely. Much of this complexity is invisible during daily wear, but each part plays a critical role in performance and reliability.

The factory floor brings the entire process into focus. Rows of automated systems and robotic arms assemble pods with precision, while technicians oversee quality checks at every stage. Each pod undergoes strict testing to ensure it meets medical-grade standards before ever reaching a box or a user. The scale and coordination of the operation make it clear how much expertise and care go into producing a device trusted 24/7 by people around the world.

This factory tour is just the beginning. More insights, surprising discoveries, and behind-the-scenes moments are featured throughout the full video above. For anyone curious about how the Omnipod is made—or how diabetes tech continues to evolve—this deep dive offers a rare look inside the heart of a device that has changed so many lives.

Disclaimer: Diabetech content is not medical advice—it’s for educational purposes only. Always consult with a physician before making changes to your healthcare.