The present invention relates to medical devices and methods of manufacturing medical devices. The application describes method of manufacturing a medical device where at least one insert (20) is provided with a first sheath including an inner sheath body (24) and one or more sheath projections (26), such that the insert (20) and the first sheath can be supported by the one or more sheath projections (24) within a mould chamber, and a second sheath (28) is injection moulded about the inner sheath body (24) and the at least one insert (20), between the one or more sheath projections (26). The method of manufacturing comprises the following steps: (a) providing at least one insert and a first sheath for the at least one insert, the first sheath including an inner sheath body and one or more sheath projections, (b) providing a second injection moulding tool having a second mould chamber, (c) locating the at least one insert and the first sheath within the second mould chamber, such that the at least one insert and the first sheath are supported within 10 the second mould chamber by the one or more sheath projections, and (d) injection moulding a second sheath about the inner sheath body and the at least one insert, between the one or more sheath projections. Wherein the device may be a guide or introducer for a tracheal tube, may comprise a stylet portion and a bougie portion. However, other devices that may include this type of arrangement, include toothbrushes for ITU oral care.
