When designing wearable medical devices, the focus often falls on the hardware. However, there is another critical component that is often overlooked—the adhesive. Adhesives are what hold these devices in place, ensuring they stay on the body and function as intended. In our recent Tape Lab Summit, I had the pleasure of speaking with Mike Muchen from Avery Dennison, who shared his extensive knowledge on the subject.
1.The Role of Adhesives in Medical Devices
Adhesives are more than just the “sticky stuff” that holds a device in place. They are integral to the device’s performance, comfort, and wearability. As Mike explained, “Without the right tape, the device simply doesn’t work as intended.” This is especially true in medical applications where devices need to stay in place for extended periods, often while the patient is moving, sweating, or showering.
2.The Challenge of Sticking to Skin
One of the most unique challenges in designing adhesives for medical devices is the nature of the substrate—human skin. Unlike other surfaces, skin varies greatly from person to person. Factors like skin type, oil production, moisture, and even hair can affect how well an adhesive bonds. This variability makes it essential for device designers to test adhesives on real people early in the process.
Mike highlighted that “testing prototypes on a small cross-section of people can provide invaluable insights,” allowing designers to understand how their device will perform in the real world.
3.Early Testing is Key
Waiting until the later stages of development to test adhesives can lead to costly delays. That’s why Mike emphasized the importance of early testing. Even a small group of five to ten people can reveal issues that might not show up in a lab environment.
“We get so hung up on full-blown clinical studies,” Mike shared. “But early prototype testing can help avoid larger problems down the road.”
4.Choosing the Right Adhesive
There are many different types of adhesives used in medical devices, each with its own benefits and drawbacks. Acrylic adhesives are the most commonly used because they offer a good balance of cost and performance. Silicone adhesives are also popular for their gentleness on the skin, but they may not offer the same durability for long-term wear.
Mike noted, “It’s all about compromise. No adhesive is perfect. It’s about finding the right balance between adhesion strength, comfort, and wear time.”
Conclusion:
In the world of wearable medical devices, adhesives play a far more critical role than many realize. By involving adhesive experts early in the design process and conducting thorough real-world testing, device manufacturers can avoid common pitfalls and ensure their products perform as expected. At Avery Dennison, we are proud to support this critical aspect of device design, helping to bring innovative, life-saving technologies to market.
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