The manufacturing reshoring movement has accelerated post-COVID, but full reshoring to the US is often cost-prohibitive. Nearshoring to Costa Rica offers a compelling middle path: North American proximity, time zone alignment, and supply chain resilience at 35–55% of US manufacturing cost.
The Reshoring Math
Full reshoring to the US restores supply chain proximity but typically raises manufacturing costs 50–200% over current offshore production. Nearshoring to Costa Rica achieves 70–80% of the supply chain resilience benefit at 30–50% of the cost premium — a significantly better ROI profile.
Supply Chain Resilience
Costa Rica’s 2.5-hour flight time to Miami, direct Panama Canal access, and multi-route air freight options provide supply chain resilience comparable to Mexico while offering superior workforce quality, IP protection, and political stability.