Exploring Medical Device Adhesives: Materials & Applications

wearable medical device tape

In the realm of medical devices, adhesives are the unsung heroes, ensuring that devices adhere securely to the skin, wounds heal effectively, and components stay in place during medical procedures.  From wound care to wearable sensors, the right medical adhesive according to the specific application is crucial for proper functionality, security, and patient comfort. Let’s dive into the diverse world of adhesives used in medical devices, exploring the different adhesive materials, applications, and key considerations. 

Acrylic Adhesives

Acrylic adhesives are versatile and known for their durability and resistance to environmental factors.

  • Applications: Used in medical tape, wound dressings, and long-term wearables.
  • Features: Offers strong bonding and long-term adhesion.

Rubber Adhesives

Rubber adhesives are versatile and known for their quick stick properties and adherence to low surface energy materials, as well as skin.

  • Applications: Used in medical tape, wound dressings, and short-term wearables, tie layers in wearable devices.
  • Features: Offers strong bonding and shorter-term adhesion on skin.

Silicone Adhesives

Silicone adhesives are biocompatible and flexible, making them suitable for skin contact applications.

  • Applications: Commonly used in wound dressings, medical tapes, and devices requiring gentle skin adhesion.
  • Features: Provides a comfortable and effective bonding solution for sensitive skin.

Hydrocolloid Adhesives

Hydrocolloid adhesives create a moist environment for wound healing and are commonly used in wound care applications.

  • Applications: Found in wound dressings, bandages, and patches for managing exudate.
  • Features: Promotes healing and provides a barrier against external contaminants.

Polyurethane Adhesives

Polyurethane adhesives offer high strength and flexibility, making them suitable for medical tubing and catheters.

  • Applications: Used in medical devices that require a strong yet conformable bond.
  • Features: Resistant to water and chemicals, ensuring stability in various medical environments.

Water-Resistant Adhesives

Water-resistant adhesives are crucial for wearable health technology intended for activities like swimming or intense workouts.

  • Applications: Used in waterproof fitness trackers, smartwatches, and other wearables exposed to moisture.
  • Features: Maintains adhesion even in wet conditions.

Cloth & Fabric Adhesives

Fabric adhesives provide comfort and breathability, making them suitable for wearables requiring continuous skin contact.

  • Applications: Used in health monitoring patches and devices where user comfort is a priority.
  • Features: Skin-friendly, allows air circulation.

Double-Sided Adhesives

Some wearables require adhesives on both sides for increased stability.

  • Applications: Used in wearables that need to adhere to both the skin and the device surface simultaneously.
  • Features: Ensures a secure attachment, preventing device shifting.

Transparent Adhesives

Transparent adhesives are ideal for wearables where aesthetics and discreteness are important.

  • Applications: Used in wearables that need to blend seamlessly with the user’s skin.
  • Features: Allows for easy monitoring of the skin under the adhesive.

Get Customized Adhesives for Your Medical Device

As technology advances and patient needs evolve, the development of specialized adhesives continues to contribute significantly to the field of medical innovation. The careful selection of the right adhesive is paramount, considering factors such as biocompatibility, strength, and intended application, to ensure the seamless integration of medical devices into patient care. 

Contact us to learn more about how we can help support your creation of the next medical device.

Stick-To-Skin Adhesives – A Key Disruptor in Modern Healthcare

Transdermal patch on arm

Wearable stick-to-skin medical devices give doctors the freedom to become time and location-independent. Healthcare providers can effortlessly gather vital patient information and take appropriate action from virtually anywhere. Plus, the patient doesn’t have to spend hours on a long commute. CGM (Continuous Glucose Monitor) is a good example, which allows doctors to remotely monitor diabetics.

However, the core component that is crucial to the effectiveness of such devices is a stick-to-skin adhesive. It ensures that the device stays attached to the patient’s body for the desired period without disrupting their usual routine. Let’s take a closer look at stick-to-skin adhesives and the importance of a reliable conversion partner.

On The Cusp Of A Growth Boom

Wearable technology; a once farfetched idea, is becoming a norm in modern medicine. It would be fair to conclude that it is rewriting the way healthcare is delivered. We are used to receiving medical attention within a typical clinical establishment; however, most patients face a medical situation at home, on travel, or at work. A moment’s delay in such a state could be catastrophic.

This has given an exponential boost to the demand for wearable tech for remote patient monitoring. According to an industrial analysis Mordor Intelligence, the wearable adhesive market, which was valued at $294.21 million in 2020, is on its way to more than doubling to $617.43 million by 2026. From medical devices and patient monitors to wound closure and sports tapes, this presents a sizeable growth opportunity in every market segment.

Considerations For Designing A Winning Stick-To-Skin Product

While the patient benefits from the device itself, however, a reliable stick-to-skin adhesive is what enables the device to do its job. Let’s explore the factors that must be considered to ensure that the product meets the expected standards:

Material Considerations:
  1. Moisture Management: Stick-to-skin devices are designed to be compatible with the user’s daily lifestyle. That means it must stand up to sweat, bodily fluids, and external moisture. To counter this, adhesive materials employ the following two methods:
    1. Fluid absorption – The adhesive takes on the moisture and holds it away from the skin to prevent irritation.
    2. Moisture-vapor transmission – Tiny holes in the adhesive and carrier material allow moisture to evaporate.
    3. Getting the layer right: Designing an effective stick-to-skin product is a complicated endeavor. Several layers of materials must come together before a product starts to take shape. The designers and manufacturers must get this delicate balance just right for the product to function correctly. For example, if an adhesive used in the skin contact layer is breathable but the outer layer does not allow moisture-vapor transmission, the product won’t perform as intended.
  2. Regulatory Considerations: Bringing a medical-grade product to the market requires the manufactories to adhere to strict regulatory standards. Even a small oversight can cause significant losses – both monetary and in terms of time to the market. Here’s what to look out for.
    1. Relevant ISO Certification & Documentation: Your design, manufacturing, and supply partners must be ISO 13485 certified and compliant.
    2. Safety Tests: To ensure that the adhesives meet the required safety standards, your suppliers must be able to conduct tests such as primary skin irritation (PSI) testing, cytotoxicity screening, biocompatibility, and safety testing, and guinea pig sensitization
  3. The Right Converting Partners: Unquestionable credibility is the backbone of any enterprise that provides healthcare services and related products. This means your production and conversion partner must have extensive experience along with outstanding research and development capabilities. The Tape Lab checks all of these boxes. Let’s take a closer look:
    1. Unquestionable Credibility & Extensive Adhesive-Specific Experience: The Tape Lab brings to the table over 18 years of research & manufacturing experience in the stick-to-skin medical tech space. Some of the largest names in the industry such as Avery Dennison have entrusted us with developing adhesive solutions for their flagship continuous health monitor. We’re supremely confident we can meet and exceed your expectations as well.
    2. A Wide Range OF Stick-To-Skin Products: The Tape Lab currently offers 11 individual categories for stick-to-skin products and 6 categories for wearable medical products. Our range includes but is not limited to adhesive bras, boob tape, CBD adhesive patches, fashion tape, wearable device tape, and diagnostic tape. You can explore our full product range over here. No matter what you have in mind, you’ll find it under one roof with The Tape Lab.
    3. The Ability To Customize & Unrivaled Engineering Expertise: Do you have an idea for a unique stick-to-skin product? We can help you bring it to life. The Tape Lab excels in every facet of medical adhesive design and manufacturing. Our core competencies include designing the tapes, die-cutting the patches, layer lamination, customizing the liner releases, and full-service OEM assembly. This gives us the scale and production capacity that will empower you to bring your product to market quicker and cheaper than your competition.
    4. Strong Supplier Partnerships: What sets us apart is our rock solid supply chain. We enjoy strong relationships with leading material manufacturers in the medical adhesive space. Our partners include 3M, Avery Dennison, Berry Plastics, Adhesive Applications and Polymer Science. This ensures immediate material access and enables us to design and produce customized medical adhesive solutions far quicker and cheaper than most of our competitors.

Next Step – Book A Free Consultation

Looking for a full-service tape converter and adhesives specialist? Contact The Tape Lab today. Our experts will schedule an obligation-free call and explain how we can put our full suite of converting services to work for you.

Transdermal Topical Patches – Will They Redefine The Way Vitamins and Supplements are Delivered?

medical device adhesive

It certainly seems that way. It wasn’t long ago that transdermal patches were viewed as a novel way to cope with chronic smoking. However, as their acceptance increased over the years, they are now being utilized to deliver vitamins, supplements, as well as give consumers remedies for, pain relief, sleep, hangovers and recovery, relaxation- or any combination of all the above via a topical patch.

Let’s explore further and take a closer look at the considerations for manufacturing quality transdermal topical patches.

What Is A Transdermal Patch & Its Various Types

In essence, these are small stick-to-skin patches to administer carefully determined plant based botanicals and vitamin doses through the patient’s skin. Patients find them convenient, non-invasive, and pain-free. Moreover, the patches enable delivery in a controlled manner, therefore, eliminating sharp peaks and valleys in vitamin and supplement administration.

Transdermal topical patches usually have 5 core components i.e. backing, ingredients (vitamins and supplements), membrane, adhesive, and the liner. They can be broadly categorized into 5 groups:

The Importance Of Choosing The Right Adhesive Converter For Transdermal Patches

The adhesive plays a critical role in ensuring that the patch stays securely pasted to the user’s skin and delivers the vitamins and supplements as intended. Let’s take a closer look at the criteria the patch adhesive must meet:

  1. Seamless Skin Adherence & Removal: It should be strong enough that the patch stays put and securely adhereed to the user’s skin for the required period. However, the adhesive must be balanced enough that the user can easily remove it without any discomfort.
  2. No Residue: No one likes to scrape sticky residue off their skin. When the patch is removed, it must not leave any adhesive residue on the skin.
  3. Comfortable: The adhesive must not cause any irritation, rashes, or trigger sensitivity.
  4. Skin- Adhesive Compatibility: It should seamlessly blend the adhesive with the ingredients without causing any physical or chemical clashes.
  5. Permeation: It should not interfere with the way or the speed at which the vitamins or supplement is supposed to be transferred to the patient.

Why An Experienced Adhesive Converter Matters

Transdermal Topical patch manufacturing is a complicated process and an experienced converter can help you stay competitive by eliminating unnecessary costs and significantly shortening the time to market.

  1. End-To-End Patch Design & Development: A knowledgeable converter can help you with any phase of the design and manufacturing process. E.g. it can help you design the required delivery system patch. What you’ll get is a well-made transdermal topical patch perfectly sized and designed to function seamlessly with the intended area of the body.
  2. Selection Of The Correct Pressure-Sensitive Adhesive: A reliable adhesive converter will ensure that the patch stays pasted to the user for the intended period and can stand up to sweat, dirt, and daily activity without causing any discomfort or skin damage.
  3. Consistent Patch Quality: A seasoned convertor will ensure that patch is made to deliver a consistent dosage.
  4. Regulatory Compliance: You will never have to worry about any compliance issues if you work with a converter that is cGMP certified.
  5. Desired Patch Shape & Size: Transdermal Topical patches have various uses, which may require the patch to be of a certain shape or size. An experienced converter brings to the table with numerous die-cutting, slitting, and sheeting capabilities, therefore, giving you the freedom to design and manufacture the patch in any shape or size. Moreover, an expert converter will eliminate material waste and help further reduce your per unit cost.
  6. Continuous Access To Critical Patch Making Materials: Experienced convertors have ties to major suppliers and can help you source the premium materials to make quality patch products that stand out in the marketplace.

What Sets The Tape Lab apart

That is indeed a relevant question. Let’s see how The Tape Lab can help bring your transdermal topical patch products to the market quicker and cheaper.

  1. A Wide Range Of Transdermal Topical Patches: No matter what type of transdermal topical patch you have in mind, we can bring it to life. And we aren’t just limited to patches. The Tape Lab offers an extensive range of stick-to-skin products such as adhesive bras, boob tape, fashion tape, wearable device tape, and diagnostic tape. You can explore our full product range over here.
  2. Unquestionable Credibility & Extensive Adhesive-Specific Experience: The Tape Lab brings to the table over 18 years of research & manufacturing experience in the stick-to-skin medical tech space. Some of the largest names in the industry such as Avery Dennison have entrusted us with developing adhesive solutions for their products. We’re supremely confident we can meet and exceed your expectations as well.
  3. Strong Supplier Partnerships: What sets us apart is our rock solid supply chain. We enjoy strong relationships with leading material manufacturers in the medical adhesive space. Our partners include 3M, Avery Dennison, Berry Plastics, Adhesive Applications and Polymer Science. This ensures immediate material access and enables us to design and produce customized adhesive solutions a lot quicker and cheaper than most of our competitors.

Next Step – Book A Free Consultation

Looking for a full-service tape converter and adhesives specialist? Contact The Tape Lab today. Our experts will schedule an obligation-free call and explain how we can put our full suite of converting services to work for you.

How Innovative Adhesive Solutions Are Transforming Continuous Health Monitoring & Wearable Medical Tech

Medical Wearables

We may not realize it, but the use of continuous health monitors is quite common – especially within the Global healthcare systems. As of 2020, over 23 million patients in the US alone utilized some form of continuous and remote health monitoring and this number is expected to hit 30 million by the year 2024.

Let’s dig a bit deeper and see how far the modern continuous monitoring tech has come and its impact on how we approach medical care. We will also shed light on how material converting and production partners are helping to bring continuous enhancements within the wearable med tech space.

What Exactly Is A Continuous Health Monitors (CHM)?

As the name implies, it is a medical device that monitors a patient continuously. The goal is to gather data on the patient’s primary health indicators and relay the information to concerned medical caregivers. In most cases, these are wearable devices that the patient can stick onto their body while carrying out their usual daily activities including working out or taking a shower.

Why It Matters?

While the technology may still be young; we’re already seeing its tremendous potential in simplifying healthcare. For starters, it can significantly reduce the time patients spend commuting to their doctor’s office or the hospital and then waiting there for the physician.

During a 2015 study, Harvard Medical School discovered patients on average spend 2 hours on a hospital visit. Continuous health monitors can minimize or almost eliminate these visits in many instances. For example, someone with a chronic heart issue can leverage it to share their data on vital health indicators and get instant feedback from their consultant rather than making the long commute.

Not only is it convenient but such devices may also help manage medical emergencies much better. The constant flow of primary health data enables doctors to take immediate action. Moreover, by minimizing patient visits, these gadgets can significantly improve the efficiency of medical facilities by reducing patient pressure.

The Role of Reliable Adhesive Solutions in Quality Wearable Devices to the Market

Depending on the patients’ needs, they may choose to wear such a device for up to 3 weeks. This means the device must be able to withstand the rigors of daily life without fail. A reliable adhesive solution ensures that the device stays securely attached to the patient’s body for the intended period. Let’s take a closer look at how advanced medical adhesive solutions add to the utility of these devices:

  • Makes It Suitable For An Active Lifestyle: Just because a patient needs to be continuously monitored shouldn’t mean that they cannot commit to normal daily activities such as school, runs, working out or a hike on the weekend. This, however, means that the device must deal with sweat, moisture, and an occasional bump. A reliable adhesive ensures that the device stays put and performs well under normal push and pull of the human body.
  • Ergonomics & Comfort: Let’s be honest. The idea of something continuously sticking to your body is not very appealing. That said, certain health conditions such as diabetes may require patients to wear glucose monitoring devices for weeks. A well-designed adhesive system guarantees that the patient can wear the device comfortably for extended periods without the risk of skin rashes or irritation.

The Importance Of A Reliable Converting & Production Partner

Unquestionable credibility is the backbone of any enterprise that provides healthcare services and related products. This means your production and converting partner must have extensive experience along with outstanding research and development capabilities.

The Tape Lab checks all of these boxes. Let’s take a closer look:

  • Trusted By Global Wearable Medical Tech Brands: The Tape Lab brings to the table over 18 years of research & manufacturing experience in the stick-to-skin medical tech space. Some of the largest names in the industry have entrusted us with developing adhesive solutions for their flagship continuous health monitor. We’re supremely confident we can meet and exceed your expectations as well.
  • Strong Supplier Partnerships: What sets us apart is our rock solid supply chain. We enjoy strong relationships with leading material manufacturers in the medical adhesive space. Our partners include 3M, Avery Dennison, Berry Global, and Dermamed. This ensures immediate material access and enables us to design and produce customized medical adhesive solutions far quicker and cheaper than most of our competitors.
  • Unrivaled Adhesive Engineering & Production Expertise: The Tape Lab excels in every facet of medical adhesive design and manufacturing. Our core competencies include designing the tapes, die-cutting the patches, layer lamination, customizing the liner releases, and full-service OEM packaging. We’re equally proficient in the design, manufacturing, and packaging of stick-to-skin wearables. Moreover, each tape component is manufactured in our ISO-8 certified clean rooms.

Next Step – Book A Free Consultation

Looking for a full-service tape converter and adhesives specialist? Contact The Tape Lab today. Our experts will schedule an obligation-free call and explain how we can put our full suite of converting services to work for you.

References

  1. https://blog.prevounce.com/27-remote-patient-monitoring-statistics-every-practice-should-know#:~:text=Consumer%2FPatient%20Statistics&text=A%20survey%20conducted%20by%20Insider,services%20and%20tools%20in%202020
  2. https://aabme.asme.org/posts/innovations-in-continuous-health-monitoring

How wearable health monitors are changing medicine

Medical Wearables

Use of wearable health monitors is on the rise as preventative care is becoming more important than ever in the healthcare industry. Remote patient monitoring tools like glucose monitors, cardiovascular monitors and new all-purpose health monitors can capture real-time, medical-grade data to share with physicians and members of a patient’s care team. These highly specialized devices need to be able to collect precise data from just below the skin without interference or data contamination caused by the device’s adhesive. That presents a significant challenge to device manufacturers and product developers. Let’s take a closer look at how the industry is changing and what medical device manufacturers need to consider to develop successful wearable medical health monitors.

Innovations in wearable health monitors

Wearable health monitors have progressed significantly in recent years thanks to technological advancements, particularly in 3G and 4G technology (and soon 5G). Medical devices like constant glucose monitors (or CGM), ECG monitors and stickers that monitor biomarkers are now more lightweight, low profile and are able to provide more in-depth analysis of patient data. These characteristics have made these products popular with both patients and practitioners alike, and even as they’ve gained widespread adoption, there is still significant room for growth in the wearables market.

As they say, the only constant is change, and there have been several recent developments that may move the industry toward even more advanced stick-to-skin wearable health monitors. In February of 2021, researchers at the University of California San Diego announced they had created a new stretchable stick-to-skin patch that acts as an all-in-one health monitor. The device can track not only a user’s vital signs, but also glucose, lactate or caffeine levels. According to the press release, it is “the first wearable device that monitors cardiovascular signals and multiple biochemical levels in the human body at the same time.”

Also in 2021, a team in Japan announced their own new “ultra-thin, lightweight e-skin” that can monitor vital signs and was specifically designed for the needs of older users. The flexible material is made using polyvinyl alcohol and a layer of gold and is applied to the chest using water. The device can be worn up to 10 days without causing damage to the user’s skin.

It remains to be seen how quickly medical device manufacturers may adopt some of these new techniques and applications. But the demand for continuous remote monitoring isn’t going away and experts project sizeable market growth over the coming years. That means there is significant opportunity for manufacturers of all types of wearable medical health monitors.

Considerations for medical device manufacturers

The key to innovation in this space is finding adhesive solutions and medical tapes that facilitate strong device performance while providing optimal user comfort. That means product developers have to account for things like:

Wear time – Some wearable health monitors are intended to be worn continuously for 10 to 30 days, or even longer in some cases. Tapes and adhesives need to be strong enough to maintain hold throughout the intended wear time without damaging the skin.

Biocompatability – Product developers need to consider not only biocompatibility in the traditional sense of toxicity and immunological responses, but also user comfort. Manufacturers need to ensure the tape or adhesive doesn’t irritate or damage the skin, particularly during the removal process.

Application and removal process – Does application require water or another agent to activate the bond? Can the product be removed by the user themselves, or will they need professional medical assistance? The tape or adhesive you choose will have a major impact on patient autonomy and the practical application of your device.

Additional adhesives – Active individuals may want to add their own tapes or adhesives to help ensure their wearable health monitor stays in place. Medical device manufacturers may want to offer guidance to customers on which adhesives and tape solutions are both safe and compatible for use with their products.

The future of healthcare

Wearable health monitors offer convenience and continuous monitoring that helps prevent medical issues and create better health outcomes for patients. And that’s why they’re here to stay. As new technology drives innovation, medical device manufacturers are finding new ways to capture and analyze vital patient data in the home or a clinical setting.

But product performance will ultimately come down to the tapes and adhesives used to adhere the device to the body. By partnering with a medical tapes and adhesives converter that can provide expert guidance on materials selection and converting services to help you streamline the manufacturing process, you can create innovative products and keep your organization at the leading edge of the healthcare and medical device industry.

Looking for a full-service tape converter and adhesives specialist? Contact The Tape Lab today and see how we can put our full suite of converting services to work for you.

Transdermal patch development and converting 101

Close-up of a photo-etched metal sheet.

The science of skin has come a long way in recent years, and transdermal patches are now a widely popular delivery method for a host of cosmetic, therapeutic and pharmaceutical treatments. Having gained widespread acceptance among consumers, the market for stick-to-skin patches can be very lucrative. To speed the development process and avoid costly issues, here are some things to consider when embarking on transdermal patch development.

The market for transdermal patches

Whether you’re talking about B12 patches, melatonin patches or even delivery systems for manuka honey, transdermal patches are in high demand. Overall, the market for transdermal patches was estimated at around $17.6 billion in 2020. Projections show that growing to around $30.5 billion by 2026.

Many companies are looking at manufacturing CBD patches in particular because the CBD market alone is estimated at nearly $3.5 billion, with projections showing significant future growth. CBD sales are expected to reach roughly $13.4 billion by 2028.

However, taking advantage of the transdermal patch market is no easy feat. In 2019, the CEO of one pharmaceutical company estimated that “the cost of developing a novel molecule-patch combination is nearly $2 billion.” But that same CEO estimated “the cost of developing a generic transdermal patch is less than 5% of the cost of a novel patch.”

This is where a tape converting partner can provide significant value. Instead of reinventing the wheel and incurring all the associated costs, a converter can provide tried-and-true methods that speed product development and eliminate headaches in the process.

For tips on how to take stick-to-skin products from concept to commercial production, download our ebook, Designing and Producing Wearable Stick-to-Skin Products.

Converting services for transdermal patches

Transdermal patch development is almost always easier, faster and cheaper when done in partnership with a tape converting services company. That’s because an experienced tape converter that can both formulate custom adhesives for transdermal patches and has the capabilities to die cut and package your patches can assist at nearly every stage of the product development process — from prototyping to packaging.

An experienced converting partner can help you:

Design your transdermal patch

  • A knowledgeable converter can help you design a delivery system (i.e., matrix patch or pre-dosed patch) that can deliver the intended therapeutic through the adhesive layer.
  • Sizing of the patch and location on the body for the patch are paramount in the success of the product. An experienced tape converter who knows the transdermal and stick-to-skin market is essential for the success of your overall design.

Select the right type of pressure sensitive adhesive

Ensure consistency in the finished product

  • Consumers expect (and regulators demand) a consistent payload or dosage from transdermal patch products.
  • Reliable converting processes help ensure each patch delivers a consistent experience.

Choose materials for the carrier and liner layers

  • A converter with ties to major suppliers can help you source the premium materials you need to make products that stand out in the marketplace.
  • Extended tape liners make products easier to apply for consumers.
  • A converter with full packaging resources can be your full turnkey solution to launching and maintaining a consistent supply chain.

Cut materials to the desired shape

  • Whether you want squares, ovals or a butterfly shape, a converter with an array of die cutting, slitting and sheeting capabilities can create the ideal shape for your application.
  • A trusted partner can also help organize production to cut down on wasted material.

Maintain regulatory compliance

  • A converter that is ISO 13485 certified has proven they will adhere to strict guidelines to ensure quality control and help you avoid any regulatory issues.

Streamlining product development

Transdermal patch development is a complex process with a lot of hurdles to overcome before you can get products into the hands of your customers. That’s why the best go-to-market approach is often to seek out a converting partner that offers full service private labeling for every aspect of your patch. For example, The Tape Lab can formulate safe stick-to-skin adhesives, laminate materials to create the finished patch, die-cut patches to the appropriate size and even package products for patch manufacturers. This allows us to act as a one-stop shop for all your transdermal patch production needs. Consider partnering with a trusted converter early in the product development process so you can streamline manufacturing and achieve commercial production faster.

Are you looking to develop transdermal patches and expand your business? Contact The Tape Lab and put our knowledge and industry-leading capabilities to work for you.

Manufacturing CBD patches: An introduction for product developers

Woman applying a nicotine patch to her arm.

CBD products absolutely exploded in popularity in recent years, and the market doesn’t show any signs of slowing down. In 2021, the CBD market is estimated at around $3.5 billion, but is expected to grow to nearly $13.4 billion by 2028. Because CBD is still relatively new, there is ample opportunity for manufacturers to introduce new products — like CBD adhesive patches — and gain significant market share. Manufacturing CBD patches requires a thoughtful approach that balances product performance needs and overall user experience. Here’s a quick introduction to help product developers create CBD patches quickly and efficiently.

Why manufacture CBD patches?

There are a lot of CBD products on the market: gummies, lotions, tinctures, vaporizers, oils and much more. So, why would consumers want CBD patches in particular? As it turns out, transdermal CBD patches offer a number of advantages over other products, including:

  • Avoids the “First Pass Effect” where the body’s metabolism limits the effectiveness of oral drugs
  • Consistent doses (compared to variable or hard-to-measure doses using CBD lotion or similar products)
  • Feels more professional/medical
  • Controlled and consistent release of CBD compounds
  • Easy to apply and remove

Types of CBD patches

From a manufacturing perspective, there are two main types of CBD patches: matrix patches and pre-dosed patches.

Matrix patches – These patches are typically composed of five distinct layers (peel-off liner, matrix layer, separating layer, adhesive layer, backing layer) and start working instantly because the CBD is infused directly into the matrix layer that touches the skin.

Pre-dosed patches – The most common type of CBD patches on the market, these patches typically have fewer layers because the CBD is compounded into the adhesive and not infused into the patch itself. The CBD level is controlled and evenly distributed on the patch to release a steadier CBD delivery rate compared to the tapered release experienced with matrix patches. Also, the pre-dosed CBD patches are absorbed by the skin and avoid the “first pass effect” by not utilizing the GI tract.

The type of design used can impact product performance. So, engineers will need to think critically about product goals before choosing a specific type of patch. Many CBD patches are made with permeation enhancers to help CBD cut through skin’s natural defenses and reach the bloodstream. The strength of CBD patches can vary from 0.5mg up to 120mg or more.

Manufacturing challenges

Manufacturing CBD patches requires engineers to overcome many of the same challenges associated with other types of stick-to-skin products. Product developers need to consider the impact adhesives have on user comfort, how to ensure user mobility and how to design products that are as discreet as they are effective. Here are just some of the challenges that will need be addressed when designing and manufacturing CBD patches:

  • Adhering patches to a dynamic surface like skin that has varying textures, elasticity and other factors that can impact product performance
  • Achieving strong enough holding power to stay affixed during long wear-times, but still easy to remove with one hand without causing significant discomfort
  • Managing moisture from sweat, water and natural oils without compromising adhesive performance
  • Ensuring the product is “breathable” enough so it doesn’t damage skin

An experienced converter can help product developers choose the appropriate materials and adjust designs to craft effective CBD patches that users will want to wear.

For insights on how to bring stick-to-skin products to market quickly and efficiently, download our ebook, Designing and Producing Wearable Stick-to-Skin Products.

Tailoring products to user preferences

To create the perfect CBD patch, engineers need to fully understand who their customers are and why they are using these products in the first place. This can be challenging as CBD products have become so mainstream that they are commonly used by people across all demographics and for a variety of purposes. For instance, some athletes use CBD to aid in their recovery process, and many professionals use it to destress after a long day. What does this type of more casual use say about how these products should be designed? On the other hand, some people use CBD as part of their medical care, seeking to reduce seizures, provide pain relief and even assist in cancer treatment. What kind of design, packaging and materials considerations are most appropriate for these types of users? By considering these kinds of questions, product developers can create CBD patches that are perfectly tailored to user preference and needs.

Opportunity awaits

In a growing market with customers who are willing to try new things, CBD patches represent a tremendous opportunity for manufacturers. The key is figuring out how to create these innovative products quickly and on budget. By partnering with an experienced converter that can help design, develop and manufacture CBD patches, health and wellness brands can capture market share and position themselves for significant growth in the years ahead.

Have an idea for a new CBD product? The Tape Lab has the knowledge, experience and capabilities to bring your vision to life. Contact us to see how we can help you gain traction in the CBD market.

Patient comfort and medical stick-to-skin products

Various sizes of adhesive bandages on blue background.

Medical stick-to-skin products represent a significant opportunity for manufacturers because of how frequently they are used in today’s healthcare industry. Patient monitors, wound dressings, sensors, surgical tape, diagnostic tape and other wearable adhesive products have all become critical components of modern approaches to patient care. But in order for these products to be effective, manufacturers need to limit patient discomfort as much as possible, particularly for outpatient applications. Not only that, but the complexity of these items make them more akin to consumer electronics goods than other tape products. So, there’s a lot you need to think about when creating a product that will be successful in the market. Here’s a look at some of the top issues manufacturers need to consider when developing comfortable and effective medical stick-to-skin products.

The pillars of medical stick-to-skin products

When developing medical stick-to-skin products, there are three main concepts every manufacturer needs to keep in mind above all others:

Autonomy – In an in-patient setting, medical professionals can assist with applying and removing stick-to-skin medical tape. But for outpatient care, patients need to be able to manipulate devices themselves, sometimes with one hand. So, product developers should use adhesives that won’t be too painful or difficult to remove while also considering how the liner system and overall design of the product impacts a patient’s autonomy.

Discretion – There is some expectation in an in-patient setting that medical devices may be somewhat intrusive or would otherwise be considered unsightly in other circumstances. In other words, medical devices aren’t expected to be especially discreet. But for outpatient applications, it’s another story. Product developers need to design products that can be worn discreetly while still achieving intended performance goals.

Mobility – Regardless of where the patient is, stick-to-skin medical devices need to be designed in such a way that patients can practice normal movements without damaging the device or hindering its effectiveness. Product developers need to consider activities like showering, exercising, sleeping and other natural, daily movements when designing devices and selecting materials.

By developing products with these principles in mind, medical device manufacturers can create comfortable products that work for real-world applications and achieve the desired medical outcome.

Other considerations for medical tape products

Moisture management

Moisture management is important for any stick-to-skin product, but particularly for medical devices. Where wounds and other medical conditions create high moisture environments, keeping the skin as dry as possible can be key to the healing process, protecting skin from becoming damaged and having a direct impact on patient comfort. Therefore, moisture management should be a main consideration for any medical product developer.

Sweat, blood, natural oils, medicated ointments, lotions and other substances create a challenge for medical tape products because they can impact adhesive effectiveness. The key to overcoming that challenge is to select the right adhesive materials for your particular application. In short, there are two ways that adhesives manage moisture: vapor transmission and fluid absorption. Each method has distinct advantages and disadvantages, so selecting the appropriate approach will depend on the specific function of your device. An experienced engineering professional can help you select the right medical adhesives materials for each layer of your product to achieve the desired outcome.

Skin as a surface

Part of what makes medical stick-to-skin products so challenging to develop is that skin is an incredibly dynamic surface. Cells are constantly regenerating, the body exudes fluids, the age of skin impacts its properties and the entire surface is elastic. Accounting for all of these factors is no easy feat. So, partnering with a converter that has experience in the medical industry can help you go from concept to commercial production by offering guidance and support throughout the product development cycle.

Optical clarity for site checks

If treatment providers need to be able to visually inspect the application site without removing the stick-to-skin product, you will need to choose optically clear materials, including your adhesives. This type of product need should be identified early in the development cycle so you can streamline materials selection and bring your product to market faster.

Whether you’re developing a new type of bandage or a truly revolutionary product that will forever change the practice of medical care, patient comfort always needs to be a top consideration. That starts with selecting the right materials and making the right design decisions. By staying focused on both patient and product needs, you can develop great medical products that help improve the lives and health outcomes of your users.

Have an idea for a stick-to-skin medical device? Contact The Tape Lab and our experienced engineers can help enhance your process from concepting to commercial production.