Sterilizing today’s complex medical devices is more challenging than ever. As devices become smaller, more intricate, and incorporate advanced materials and electronics, manufacturers must ensure sterility without compromising performance, safety, or regulatory compliance. From navigating material compatibility to validating sterilant penetration in complex geometries, the sterilization process requires careful planning and expertise. In this article, we explore the most common sterilization challenges manufacturers face—and the strategies that can help ensure safe, compliant, and scalable production.