Perfecting the Manufacturing of Wearable Medical Devices

With the fast-paced advances in wearable electronics, precision and efficiency are critical to staying ahead of the competition and meeting customer demands. At Herrmann Ultrasonics, we offer cutting-edge ultrasonic welding technology specifically tailored to health monitoring devices such as Continuous Glucose Monitoring (CGM) systems that will accelerate and improve the efficiency of your production processes. Start your project now with us as your medical wearable devices manufacturer partner!

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Wearables Device Brochure

Brochure: Wearable Devices
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Why Ultrasonic Welding for Wearable Medical Devices?

Ultrasonic welding is a commonly used method in the manufacturing of medical devices, including CGM systems. Our technology utilizes high-frequency ultrasonic vibrations to create friction and generate heat, causing the materials to fuse together.

As a medical wearable devices manufacturer, we offer you several advantages with our ultrasonic welding technology:

  • Hermetic Sealing: Ultrasonic welding can create strong, hermetic seals that are essential for protecting sensitive components within wearable biomedical devices from environmental factors.
  • Clean Process: Ultrasonic welding doesn't involve glues, solvents, or other contaminants. This makes the medical devices more comfortable to wear and avoids skin irritation, which is often caused by chemical adhesives. It also means the process requires no additional materials or consumables and generates significantly less waste. 
  • Reduced Mechanical Stress: The welding process is gentle, leading to reduced mechanical stress on delicate components of wearable medical device systems.
  • Minimal Heat Generation: Ultrasonic welding generates heat primarily at the bond line, minimizing the risk of heat affecting sensitive components or materials in wearable healthcare devices.
  • Cost Savings: Unlike other assembly methods that require additional materials like adhesives, ultrasonic welding eliminates the need for consumables. This can simplify the manufacturing process and reduce associated costs.
  • Enhanced Comfort: The welds created by this process can be performed within the recesses of each part. This means the finished devices will have no sharp of rough edges, ensuring the comfort of the patients who wear them. Wearable technology companies that can provide devices that are comfortable to wear have an edge over their competitors. 
  • Faster Turnaround: Compared to other methods of joining components, ultrasonic welding can produce welds in seconds. This ensures the most efficient and fastest cycle times, cutting down on production time and increasing throughput. 
  • Stronger Welds: Because it creates bonds at the molecular level, the strength of a bond created through ultrasonic welding is much higher than with other methods. In most cases, the area of the bond is as strong as the base material, resulting in practically no weak spots and enhanced resistance to force. This means the resulting product will be much more durable than if a different technique had been used. 
  • More Compatibility: Another key advantage of ultrasonic welding in the medical industry is its versatility. The process is compatible with a large number of thermoplastic materials and is capable of joining dissimilar materials. This provides manufacturers with more options without compromising the quality of the finished product. 

Controller showing settings manual, semi-auto and automatic.

Real-Time Feedback and Quality Assurance: Perfecting the Welding Process

Get an unprecedented overview of your production processes! Our Ultrasonic Welding technology allows for real-time feedback on bond integrity, enabling instant adjustments to maintain superior quality.

To ensure process safety and traceability, our integrated FSC software module records changes to system parameters and user actions in electronic audit trails. At the same time, the DataRecorder software module allows the permanent storage of process results on a PC directly from the ultrasonic generator. This way, both welds and user actions can be recorded completely in the interest of a holistic production logbook.

Benefit from a more reliable and safe production:

  • Process Monitoring: Tracks welding parameters in real-time, essential for process optimization.
  • Quality Assurance: Our smart controller system identifies any deviations, ensuring every device meets the required standards.
  • Precision: Ultrasonic welding offers precise control over the welding process. This accuracy is crucial for wearable devices, where components need to be precisely aligned to ensure sensor accuracy and reliable performance.

With minimal welding times and real-time quality control, ultrasonic welding is perfect for integration into existing or new high-speed manufacturing processes. We will consult with you on the integration of our modules so that you can benefit from the advantages of our technology as quickly as possible. 

  • Automation: Ultrasonic welding can be easily integrated into automated manufacturing processes, streamlining production and minimizing human intervention.
  • Fast Cycle Times: Fast, reliable bonding of plastic housings ensures your production line operates at peak efficiency. Rapid assembly and seamless integration mean quicker deliveries to meet market demands, giving you a competitive advantage.
  • Consistent Results: The controlled and automated nature of ultrasonic welding helps ensure consistent results across wearable devices even at highest production speeds, reducing variations in quality.

While ultrasonic welding offers numerous advantages, it's important to note that its suitability depends on the specific design and materials of the system’s components. Our experienced experts will therefore not only consult you on the development of an ultrasonic welding process. They can also advise you on the development of your application so that you can benefit from the numerous advantages of ultrasonic welding.

Top 5 Reasons for using Ultrasonics for Demanding Medical Device Market

Choosing ultrasonics as joining technology for your medical device will speed up your production, increase the output and improve the quality of your product.

Start your welding project with us to benefit from its advantages:

  1. Improved Time-to-Market: Faster production cycles mean quicker time-to-market, a critical KPI for staying ahead of competitors and meeting customer demands promptly. Using ultrasonic welding keeps your production on track and helps your products reach those who need them as soon as possible.
  2. Increased Output: Ultrasonic welding only needs fractions of seconds for lasting connections, thereby accelerating your production and enabling you to produce more units within the same timeframe, boosting productivity metrics. Compared to other methods, ultrasonic welding cuts down on cycle times and enhances efficiency.
  3. Reduced Defect Rates: Real-time quality feedback minimizes defects, leading to lower reject rates and reduces the need for costly rework or replacements. This is crucial for ensuring higher customer satisfaction rates as well as keeping costs from spiraling out of control.
  4. Increased Product Quality: Without chemical joining agents, skin compatibility and wearer comfort are improved, while resource consumption and costs can be reduced simultaneously. Those who use your devices will be more satisfied with the end results, helping to build your brand and putting you at an advantage over your competitors.
  5. Enhanced Efficiency: Fast cycle times and optimized workflows enhance operational efficiency, ensuring your resources are utilized effectively. Using this process within your production cycle can be one of the best ways to achieve your goals and provide your customers with the highest-quality products.

Brochure: Wearable Devices
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Ready to Transform Your Production Process?

Herrmann Ultrasonic leverages decades of expertise and innovation to provide comprehensive solutions for wearable medical devices and Continuous Glucose Monitoring (CGM) devices. Our commitment to research and development ensures that our technology always aligns with industry trends, meeting the evolving needs of the medical device sector.

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Picture Selina Kiefer
Business Development
Selina Kiefer and Team