To cost effectively mass produce wearable biosensors, vertical integration and assembly operations is key. Having the ability to print conductive inks on flexible substrates and fully perform converting operations (such as lamination of medical grade hydrocolloids, adhesives, non-woven and foam layers, hydrogel dispensing and or placement and final packaging) in SMT components and any connections on the non-patient side of the patch (ensures patient comfort). Have been successful in .010” diameter via hole print filling in order to have continuity between skin contact and a assumed communication device.
Process for manufacturing biosensors employ screen printing, laser cutting, lamination, and adhesives. Screen printing of various conductive inks, such as but not limited to silver, silver/silver-chloride, carbon, zinc, gold, dielectric, etc. In addition, Surface-Mount Technology (SMT) is used if components are required. There are several key converting processes, including die-cutting, lamination of medical grade foams and adhesives, as well as the dispensing and placement of medical grade hydrogels and final packaging. The role of printing through holes methods, which allow for connections between the top and bottom printed circuits and up to 6 layers per side.
Majority of applications, biosensor manufacturing involves a supply chain of companies since few companies possess all the necessary capabilities. Required functions in detail as follows:
- Oven dwell typically ≤10 minutes ≤140°C
Slip sheet or interleaf may be required to prevent ink rub-off since carbon inks tend to be soft and transfer to backside of substrate when stacked or wound in rolls
Patterning of spacer/adhesive layer
Patterning of lid or top layer
Dispensing & drying/conditioning of functional material
Option – Cartridge or Cassette type configuration
Sheet/Roll to Cards