This article is a chapter from our comprehensive report on 3D printing with wear-resistant plastics. &nbsp;If you're interested in diving deeper and accessing the full report, we invite you to download it below. Gain a holistic understanding and benefit from the complete insights we've gathered. Don't miss out!<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMTg2MzEzNTc0LWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"> <iframe width="540" height="305" src="https://c8056756.sibforms.com/serve/MUIFAI3PJfiab43rzSudutrE1NSBLWBrIYMuTLjuk7V8EDM15HG0D1C6wjdMHZMiff18ZTqCrBhOkxMaCwPGCk91mWqwuJKESYPi5C21fZjDAFoFa8ZDKmVUuECd05z1jZyX_SNjhMolzGuDIRFD1yvyWVOk7LzkFEgXffPqTznKc-H6-CFw0r9KIcY9W66Oq2bcIK4X1RZRsLl1" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block;margin-left: auto;margin-right: auto;max-width: 100%;" class="fr-draggable"></iframe> <h2 dir="ltr" id="isPasted">High-Performance Thermoplastics</h2>3D printing allows creating and producing complex object geometries from a variety of materials. It has significantly reduced the design-manufacturing cycle, production cost, and material waste. This can be attributed to the fact that 3D printing relies on digital CAD data, which allows for multiple iterations of a product to be produced faster and cheaper than the traditional manufacturing methods. Furthermore, the precise layer-by-layer fabrication process of 3D printing eliminates the need for sculpting the final product and generates minimal residual materials.[1]As technology advances, the variety of materials used in 3D printing has also increased. However, one of the challenges in 3D printing is the need for advanced materials that can match performance and high fabrication standards.[2]&nbsp;Thus, the sector has been focused on developing new high-performance materials that can improve the efficiency and speed of 3D printing and extend its properties and applications. One example is high-performance thermoplastic polymer. It is suitable for 3D printing techniques and supports the production of pieces with high strength-to-weight ratios and properties that can withstand high loads or harsh environments.[3]<h2 dir="ltr">Medical Applications</h2>In medical applications, there are high-performance plastics such as PEI, PEEK and PEKK in use. These are base materials, not optimized for wear and friction. Printable High-performance-thermoplastics including solid lubricants are for example, igus’ iglidur A350 and iglidur RW370. These can be processed on high-temperature FFF printers.The remarkable chemical stability and resistance of high-performance thermoplastic polymers make them well-suited for medical parts, and capable of withstanding autoclave and chemical sterilization processes.&nbsp;Professor Jumpei Arata of Kyushu University in Japan has developed a hand exoskeleton, the RELab tenoexo, using high-performance igus polymers. The exoskeleton is a fully wearable robotic hand orthosis, designed to assist people with sensorimotor hand impairment. Stroke, spinal cord injury, and cerebral palsy are examples of diseases leading to persistent hand impairment.[7]The RELab tenoexo is made up of three components: The exoskeleton comprises a hand module, a wristband sensor, and a backpack. Its design allows for a wide range of daily hand activities and therapy tasks, covering approximately 80% of all grasping activities. It has a maximum fingertip force of 6 N per finger, which makes it capable of easily grasping and lifting many everyday objects, including a half-liter water bottle.[8] <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjQyOTg1MTAyLTE2OTU2NDI5ODUxMDIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="650" height="433" id="isPasted" class="fr-fic fr-dii">ReLab's tenoex is lightweight and compact, allowing for ease of use. Image credit: igus&nbsp;<h2 dir="ltr">How does the RELab tenoex work?</h2>The patient wears a wristband and backpack while the hand module is attached to their hand using leather straps. The exoskeleton is portable and compact, able to be used during everyday life. The hand module weighs 148g, and the backpack 720g, ensuring patient comfort.&nbsp;The hand module comprises three thin leaf springs made of stainless steel placed on each other and connected by four plastic links. It provides power, precision, and lateral grasp. Additionally, a Bowden-cable-based force transmission system is attached to the middle spring. When moving forward, the fingers close, and the hand opens when pulled back. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjQyNzc0NzczLTE2OTU2NDI3NzQ3NzMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="650" height="433" class="fr-fic fr-dii">The ReLab tenoex hand exoskeleton actively supports the flexion and extension of the combined index, middle, ring, little finger, and thumb. Image credit: igusWhen the patient moves the hand, the wristband transmits electromyographic (EMG) signals to a microcomputer located in a backpack. If the patient intends to make a grasping movement, the computer detects this and activates the DC motors, allowing motion. The robotic hand orthosis also has an application that allows users to change the force range and closing speed, select between two grasp types, and configure the control system/intention detection strategies. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjQyNzc0OTIwLTE2OTU2NDI3NzQ5MjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="650" height="433" class="fr-fic fr-dii" style="width: 758px;">The device must be lightweight as well as robust. Image credit: igusHowever, the prototype faced several issues, such as the delicate finger joint structure. These elements keep the leaf springs together and have a lattice-locking mechanism. The first exoskeleton version used a 3D printer with an ABS filament. The manufacturing method and the material were unsuitable for the manufacture of finger joints due to the high friction, resulting in energy loss when the fingers moved. Furthermore, the resolution of a regular 3D printer was not precise enough to recreate the detailed structure of the finger phalanxes.Here comes the application of high-performance thermoplastics for medical purposes. ETHZ University (Eidgenössische Technische Hochschule Zurich) eventually found a solution. With the help of selective laser sintering (SLS) technology and the iglidur i6 high-performance thermoplastic from igus, researchers were able to avoid problems with high friction and low resolution,<a href="https://www.igus.eu/info/3d-print-3d-printing-service" target="_blank" rel="noopener noreferrer">&nbsp;thanks to the igus 3D printing service</a>.[9]<h2 dir="ltr">Properties of iglidur i6</h2>The iglidur i6 high-performance thermoplastic for laser sintering has proven to have an extraordinary greater wear resistance and much lower friction than conventional materials, ensuring longer service life for parts. With abrasion resistance 50 times higher than standard 3D printing materials, it's well-suited for moving applications like the RELab tenoexo. Moreover, the SLS process eliminates the need for tooling, making it suitable for manufacturing special and delicate parts.&nbsp;SLS uses a selective laser that fuses the powder material layer by layer, ensuring some advantages. For instance, unlike FDM printing, there is no need for support structures because the surrounding powder acts as a natural support, avoiding the need for post-processing. Moreover, it guarantees uniform distribution of material and good interlayer bonding, which leads to consistent mechanical properties. The unique material properties of iglidur i6 also make it ideal for creating 3D-printed finger phalanxes in an exoskeleton.[10]<h3 dir="ltr">Reducing friction</h3>The self-lubricating SLS material iglidur i6 had been specially developed for manufacturing parts subject to friction and was used successfully for manufacturing the finger joints. 3D printed finger phalanges made of high-performance iglidur i6 polymer ensure optimum force transmission. This material is ideal for moving applications and contains solid lubricants, making it easy to handle without needing additional lubrication. This feature makes it suitable for therapeutic applications.<h3 dir="ltr">Delicate parts</h3>Laser sintering as a manufacturing method is ideally suited for replicating complex geometries, filigree structures, and delicate details. This makes it possible to manufacture small volumes and one-off components cost-effectively. iglidur i6 was initially developed to manufacture worm wheels for robot joints and wear parts in general.<h3 dir="ltr">Resistance</h3>One of the most outstanding features of iglidur i6 is its resilience and abrasion resistance. A sintered gear made of this abrasion-resistant iglidur plastic was tested under the same conditions as a machined gear made of POM for two months. The gear made of POM exhibited signs of severe wear after 321,000 cycles and failed after 621,000 cycles. In contrast, the gear made of iglidur i6 continued to function after 1 million cycles, with only minor signs of wear. &nbsp;<h3 dir="ltr">Light&nbsp;</h3>The iglidur i6 is an impressively lightweight material, making it ideal for applications where weight is a key factor. For instance, it is a perfect choice for a hand orthosis that needs to be worn for long periods. It is worth noting that the hand module, which features finger joints made of iglidur i6, only weighs 148g.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMTg2OTE4MTY1LWltYWdlLmltYWdlZm9ybWF0LjEyODYuNDc2NzkwNjA2ICgxKS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">The Relab tenoex allows users to change the force range and closing speed, select between two grasp types, and configure the control system/intention detection strategies. Image credit: RELAB ETHZ There are more current benefits of the application of high-performance thermoplastics. With the help of SLS technology and iglidur i6 high-performance plastic, it is now possible to produce delicate structures of finger joints without the need for support structures. This also eliminates the need for post-processing. For example, pieces from FDM 3D prints tend to have a slightly rough surface, suggesting the need to smooth out the imperfections through sanding.[11]&nbsp;Moreover, RELab tenoexo exoskeletons are individually adapted to fit individual patients. The company developed an algorithm that adjusted the digital model of the exoskeleton to the size of the patient's hand with just a few clicks, thereby avoiding any mistakes. This means the exoskeleton can be manufactured to meet individual customer requirements quickly and without complications.In addition, with the help of an online 3D printing service tool, ETHZ scientists can order the required parts in just a few minutes. The manufacturing process is usually completed overnight, and the finished finger joints can be fitted after just a few days.This is the only manufacturing method that approaches the speed and cost-effectiveness of 3D printing where a customized small-volume manufacturer is concerned. The adaptable and fast production characteristics of this method are game changers, especially considering that conventional customization methods are complex due to molding or other tool-based methods.<h2 dir="ltr">Conclusion</h2>High-performance thermoplastics and SLS have exceptional properties, such as being friction-free, allowing for detailed and precise printing, being self-lubricating, lightweight, and easy to produce. By combining these materials, users can better support their daily activities and receive rehabilitation training.&nbsp;This article was co-authored by Ana Carla Sorgato.<hr><h2>The Engineer’s Guide to 3D Printing with Wear-Resistant Plastic Materials</h2>Explore the transformative world of 3D printing as we delve into the intricacies of using wear-resistant plastic materials. <a href="https://www.wevolver.com/article/the-engineers-guide-to-3d-printing-with-wear-resistant-plastic-materials/draft" target="_blank" rel="noopener noreferrer">This guide</a> offers engineers a comprehensive overview of material properties, applications, and best practices. Unlock the potential of durable plastics and revolutionize your manufacturing processes.<h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk5NjIyODA5OTIyLU1pdHN1YmlzaGkgQ2hlbWljYWwgR3JvdXAgIEdyb3d0aCBHYXJhZ2UgIE9wZW4gSW5ub3ZhdGlvbiBQcm9ncmFtICg2OTQgeCA0MzIgcHgpICg5MDEgeCA1NjEgcHgpICgyKS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></h3><iframe width="540" height="305" src="https://c8056756.sibforms.com/serve/MUIFAI3PJfiab43rzSudutrE1NSBLWBrIYMuTLjuk7V8EDM15HG0D1C6wjdMHZMiff18ZTqCrBhOkxMaCwPGCk91mWqwuJKESYPi5C21fZjDAFoFa8ZDKmVUuECd05z1jZyX_SNjhMolzGuDIRFD1yvyWVOk7LzkFEgXffPqTznKc-H6-CFw0r9KIcY9W66Oq2bcIK4X1RZRsLl1" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block;margin-left: auto;margin-right: auto;max-width: 100%;" class="fr-draggable">&nbsp;</iframe><h2 dir="ltr"> </h2><h2 dir="ltr">References</h2><ol><li dir="ltr">Azom. “https://www.azom.com/article.aspx?ArticleID=20017”</li><li dir="ltr">Valino, A. D., Dizon, J. R. C., Espera Jr, A. H., Chen, Q., Messman, J., &amp; Advincula, R. C., 2019. “<a href="https://www.sciencedirect.com/science/article/pii/S0079670018303976" target="_blank">https://www.sciencedirect.com/science/article/pii/S0079670018303976</a>”</li><li dir="ltr">Anniwaa “<a href="https://www.aniwaa.com/insight/am-materials/am-thermoplastics-breakdown-by-performance/" target="_blank">https://www.aniwaa.com/insight/am-materials/am-thermoplastics-breakdown-by-performance/</a>”</li><li dir="ltr">Wevolver. “https://www.wevolver.com/article/peek-3d-printing-unlocking-the-potential-of-high-performance-polymers”</li><li dir="ltr">Algarni, Mohammed; Ghazali, Sami., 2021. “<a href="https://www.proquest.com/docview/2565095716" target="_blank">https://www.proquest.com/docview/2565095716</a>”</li><li dir="ltr">Bond 3D. “<a href="https://www.bond3d.com/market/peek-medical/" target="_blank">https://www.bond3d.com/market/peek-medical/</a>”</li><li dir="ltr">ETH Zurich. "<a href="https://relab.ethz.ch/research/current-research-projects/Robotic%2520Hand%2520Orthosis%2520.html" target="_blank">https://relab.ethz.ch/research/current-research-projects/Robotic%20Hand%20Orthosis%20.html</a>”</li><li dir="ltr">Tobias Bützer, Olivier Lambercy, Jumpei Arata, and Roger Gassert (2021). “<a href="https://www.liebertpub.com/doi/abs/10.1089/soro.2019.0135" target="_blank">https://www.liebertpub.com/doi/abs/10.1089/soro.2019.0135</a>”</li><li dir="ltr">3dnatives. 2021. “<a href="https://www.3dnatives.com/en/3d-printed-finger-joints-igus-110120204/" target="_blank">https://www.3dnatives.com/en/3d-printed-finger-joints-igus-110120204/#</a>”</li><li dir="ltr">Igus. “<a href="https://www.igus.eu/info/3d-printing-application-exoskeleton" target="_blank">https://www.igus.eu/info/3d-printing-application-exoskeleton</a>”</li><li dir="ltr">All3dp “<a href="https://all3dp.com/2/fdm-3d-printing-post-processing-an-overview-for-beginners/" target="_blank">https://all3dp.com/2/fdm-3d-printing-post-processing-an-overview-for-beginners/</a>”</li></ol>

Article #2 of The Engineer’s Guide to 3D Printing with Wear-Resistant Plastic Materials.

How High-Performance Thermoplastics are Powering the Future of Therapeutic Applications

This article was discussed in our <a href="https://www.wevolver.com/profile/the.next.byte" rel="noopener noreferrer" target="_blank">Next Byte podcast</a>.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/0a80bd29-e245-4c39-8375-0c544a26f6f8?dark=false" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The full article will continue below.<hr>This article originally appeared in <a href="https://news.mit.edu/2023/implantable-device-enable-injection-free-control-diabetes-0918" target="_blank" rel="noopener noreferrer">MIT News</a> and has been republished with permission.<hr>One promising approach to treating Type 1 diabetes is implanting pancreatic islet cells that can produce insulin when needed, which can free patients from giving themselves frequent insulin injections. However, one major obstacle to this approach is that once the cells are implanted, they eventually run out of oxygen and stop producing insulin.To overcome that hurdle, MIT engineers have designed a new implantable device that not only carries hundreds of thousands of insulin-producing islet cells, but also has its own on-board oxygen factory, which generates oxygen by splitting water vapor found in the body.The researchers showed that when implanted into diabetic mice, this device could keep the mice’s blood glucose levels stable for at least a month. The researchers now hope to create a larger version of the device, about the size of a stick of chewing gum, that could eventually be tested in people with Type 1 diabetes.“You can think of this as a living medical device that is made from human cells that secrete insulin, along with an electronic life support-system. We’re excited by the progress so far, and we really are optimistic that this technology could end up helping patients,” says Daniel Anderson, a professor in MIT’s Department of Chemical Engineering, a member of MIT’s Koch Institute for Integrative Cancer Research and Institute for Medical Engineering and Science (IMES), and the senior author of the study.While the researchers’ main focus is on diabetes treatment, they say that this kind of device could also be adapted to treat other diseases that require repeated delivery of therapeutic proteins.MIT Research Scientist Siddharth Krishnan is the lead author of the <a href="https://www.pnas.org/doi/10.1073/pnas.2311707120" target="_blank">paper</a>, which appears today in the Proceedings of the National Academy of Sciences. The research team also includes several other researchers from MIT, including Robert Langer, the David H. Koch Institute Professor at MIT and a member of the Koch Institute, as well as researchers from Boston Children’s Hospital.<h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjM1MTI1ODM3LU1JVC1Jc2xldHMtT3h5Z2VuLTAyLXByZXNzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Pictured is the device submerged in water, generating oxygen (bottom) and hydrogen (top) bubbles without the need for any batteries or wires. Image: Courtesy of Claudia Liu and Dr. Siddharth Krishnan, MIT/Boston Children’s HospitalReplacing injections</h2>Most patients with Type 1 diabetes have to monitor their blood glucose levels carefully and inject themselves with insulin at least once a day. However, this process doesn’t replicate the body’s natural ability to control blood glucose levels.“The vast majority of diabetics that are insulin-dependent are injecting themselves with insulin, and doing their very best, but they do not have healthy blood sugar levels,” Anderson says. “If you look at their blood sugar levels, even for people that are very dedicated to being careful, they just can’t match what a living pancreas can do.”A better alternative would be to transplant cells that produce insulin whenever they detect surges in the patient’s blood glucose levels. Some diabetes patients have received transplanted islet cells from human cadavers, which can achieve long-term control of diabetes; however, these patients have to take immunosuppressive drugs to prevent their body from rejecting the implanted cells.More recently, researchers have shown similar success with islet cells derived from stem cells, but patients who receive those cells also need to take immunosuppressive drugs.Another possibility, which could prevent the need for immunosuppressive drugs, is to encapsulate the transplanted cells within a flexible device that protects the cells from the immune system. However, finding a reliable oxygen supply for these encapsulated cells has proven challenging.Some experimental devices, including one that has been tested in clinical trials, feature an oxygen chamber that can supply the cells, but this chamber needs to be reloaded periodically. Other researchers have developed implants that include chemical reagents that can generate oxygen, but these also run out eventually.The MIT team took a different approach that could potentially generate oxygen indefinitely, by splitting water. This is done using a proton-exchange membrane — a technology originally deployed to generate hydrogen in fuel cells — located within the device. This membrane can split water vapor (found abundantly in the body) into hydrogen, which diffuses harmlessly away, and oxygen, which goes into a storage chamber that feeds the islet cells through a thin, oxygen-permeable membrane.A significant advantage of this approach is that it does not require any wires or batteries. Splitting this water vapor requires a small voltage (about 2 volts), which is generated using a phenomenon known as resonant inductive coupling. A tuned magnetic coil located outside the body transmits power to a small, flexible antenna within the device, allowing for wireless power transfer. It does require an external coil, which the researchers anticipate could be worn as a patch on the patient’s skin.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjM1MjM0Njc0LU1JVC1Jc2xldHMtT3h5Z2VuLTAzLXByZXNzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 768px;" class="fr-fic fr-dib">This photo shows the cathode side of fully assembled device, with a United States quarter-dollar coin for scale.&nbsp; Image: Courtesy of Claudia Liu and Dr. Siddharth Krishnan, MIT/Boston Children’s Hospital<h2>Drugs on demand</h2>After building their device, which is about the size of a U.S. quarter, the researchers tested it in diabetic mice. One group of mice received the device with the oxygen-generating, water-splitting membrane, while the other received a device that contained islet cells without any supplemental oxygen. The devices were implanted just under the skin, in mice with fully functional immune systems.The researchers found that mice implanted with the oxygen-generating device were able to maintain normal blood glucose levels, comparable to healthy animals. However, mice that received the nonoxygenated device became hyperglycemic (with elevated blood sugar) within about two weeks.Typically when any kind of medical device is implanted in the body, attack by the immune system leads to a buildup of scar tissue called fibrosis, which can reduce the devices’ effectiveness. This kind of scar tissue did form around the implants used in this study, but the device’s success in controlling blood glucose levels suggests that insulin was still able to diffuse out of the device, and glucose into it.This approach could also be used to deliver cells that produce other types of therapeutic proteins that need to be given over long periods of time. In this study, the researchers showed that the device could also keep alive cells that produce erythropoietin, a protein that stimulates red blood cell production.“We’re optimistic that it will be possible to make living medical devices that can reside in the body and produce drugs as needed,” Anderson says. “There are a variety of diseases where patients need to take proteins exogenously, sometimes very frequently. If we can replace the need for infusions every other week with a single implant that can act for a long time, I think that could really help a lot of patients.”The researchers now plan to adapt the device for testing in larger animals and eventually humans. For human use, they hope to develop an implant that would be about the size of a stick of chewing gum. They also plan to test whether the device can remain in the body for longer periods of time.“The materials we’ve used are inherently stable and long-lived, so I think that kind of long-term operation is within the realm of possibility, and that’s what we’re working on,” Krishnan says.“We are very excited about these findings, which we believe could provide a whole new way of someday treating diabetes and possibly other diseases,” Langer adds.<hr>"Reprinted with permission of <a href="https://news.mit.edu/2023/implantable-device-enable-injection-free-control-diabetes-0918" target="_blank" rel="noopener noreferrer" id="isPasted">MIT News</a>" &nbsp;

MIT engineers designed an implantable device that carries hundreds of thousands of islet cells along with its own on-board oxygen factory to keep the cells healthy. Image: Felice Frankel

The device contains encapsulated cells that produce insulin, plus a tiny oxygen-producing factory that keeps the cells healthy.

An implantable device could enable injection-free control of diabetes

<a href="https://www.wevolver.com/article/the-rock-engineering-challenge" target="_blank">The ROCK Engineering Challenge</a> invited engineers, entrepreneurs, inventors, and developers to submit an idea for a part, product, or system that took advantage of the <a href="https://www.okdo.com/c/rock-shop/rock-sbc/?utm_source=wevolver&utm_campaign=rock&utm_medium=affiliates&utm_content=rock_community_winner_interview" target="_blank" rel="noopener noreferrer">ROCK single-board computers</a>.&nbsp;We received a significant number of submissions from across the globe, impressed with cutting-edge applications of single-board computers.&nbsp;The Wevolver Community Vote winner was <a href="https://www.wevolver.com/article/the-rock-engineering-challenge-finalists-and-community-vote" target="_blank">selected by our community through a public poll</a>. The Wevolver community winners of the <a href="https://www.okdo.com/?utm_source=wevolver&utm_campaign=rock&utm_medium=affiliates&utm_content=rock_community_winner_interview" target="_blank" rel="noopener noreferrer">OKdo&nbsp;</a>challenge are Marcel Ochsendorf and Sebastian Kindorf, who are developing a thermal imaging medical device.&nbsp;This product is designed to aid medical facilities by using a thermal imaging camera to non-invasively record a patient's status. The system can determine breathing status, frequency, body temperature, and movements like falls, alerting medical staff when necessary.Wevolver’s Content Director, Jessica Miley, interviewed Marcel and Sebastian to learn more about their engineering careers, what motivated them to enter the challenge, and the plans for their ideas. Jessica Miley: Hi team. Thanks for speaking with us. Let’s start by getting you guys to introduce yourselves. Marcel Ochsendorf: My name is Marcel. I am currently a Master's student in my final semester. I have a Computer Science Bachelor and am now doing electrical engineering in my Master's. I love doing engineering projects, and I have attended several hackathons and so on in the past.Sebastian Kindorf: I'm Sebastian. After I completed an apprenticeship as an electrician, I decided to continue with a Bachelor's degree, also in electrical engineering, and then graduated with my Master’s degree in April. Afterwards I worked for two months in Morocco on an automation project for sustainable irrigation.Jessica Miley: How did you two meet and start working on this project together?Sebastian Kindorf: We met when we were both working at <a href="https://home.cern/" target="_blank">CERN</a>- the International Research Center in Switzerland. We actually met accidentally, and after we talked a little bit, we realized we were on the same wavelength. He [Marcel] makes a lot of electronic projects and so do I. After a few weeks, I said, “Okay, I think we should start a project together.” We had a few ideas, then I saw Wevolver had this engineering challenge and we decided to enter. So we went to a restaurant, drank two beers and did some brainstorming!Marcel Ochsendorf: This project was born out of an experience that I had doing some work as an IT engineer in a hospital a few years ago. This hospital had problems with monitoring patients because it is really data-sensitive. In Germany, data is very regulated. For example, you cannot record a patient and then analyse it. So it's really challenging to create a device for <a href="https://www.wevolver.com/article/can-remote-patient-monitoring-improve-the-quality-of-healthcare" target="_blank">remote patient monitoring</a>. We had the idea to use a thermal camera to take a video feed anonymously, sSo you only have an abstract grayscale image with temperature information. Its not possible to clearly identify a person out of this captured image but it is possible to detect the patient's body (position, vital signs) so that patient monitoring can be done without violating the patient's personal rights and that the patient may feel uncomfortable by the "monitoring".&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjA2MTUyMTU1LU5DUE1TeXNfcHJvdG90eXBlICgyKS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">The remote patient monitoring device prototype.&nbsp;Jessica Miley: So the product addresses a problem that health institutions have of keeping an eye on a large number of patients - your product can monitor key health aspects such as breathing etc. - &nbsp;without needing staff to be everywhere at once?Marcel Ochsendorf: Yes. In Germany, and likely other countries, hospitals are very understaffed. So it’s a good solution to monitor patients without additional staff. Currently, patients are monitored by being physically attached to machines, for example, heart rate and oxygen via a finger clip.&nbsp;Jessica Miley: How does the product actually work?Sebastian Kindorf: The product primarily relies on two different sensor signals for its functioning.First, a thermal camera is utilized to record the patient's body temperature. Each individual has a unique "healthy" body temperature range, and deviations from this range can indicate potentially dangerous conditions such as hypothermia or fever. Monitoring body temperature serves as an essential indicator for determining if a patient requires closer examination.Secondly, a regular imaging camera, combined with specific evaluation algorithms, is used to derive additional parameters such as respiratory status, respiratory rate, heart rate, heart rate variability, and patient positioning. This information can provide insights into potential falls from the bed. To determine heart rate and heart rate variability, we employ remote photoplethysmography (rPPG) technology. The rPPG analyzes color changes in the skin to extract cardiovascular information.By simply transferring patient data, the hard-working healthcare workers should eventually be relieved.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjA2MTc2MDcxLU5DUE1TeXNfcHJvdG90eXBlX2JhY2t3aXRoUm9jayAoMikucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">The device aims to reduce the workload of health care workers.&nbsp;Jessica Miley: What kind of technical hurdles have you faced, and how did you overcome them or what? How did using the ROCK hardware assist in that?Marcel Ochsendorf: The main goal is to do all the sensor processing locally. In addition, secure encryption algorithms must be used. This way, no sensitive data is left on a device or forwarded to personnel. The complete evaluation runs locally on the device and only status information leaves the device. This is to comply with the strict requirement of data protection guidelines.&nbsp;Sebastian Kindorf: The Rock chip has a very good GPU and thus good possibilities for processing by algorithms or trained AIs. Image processing is therefore much faster on the Rock chip than on a Raspberry Pi, for example, where only a few frames per second of high definition image data can be processed. Additionally, ROCK's single board computers were also available during the Covid19 pandemic, compared to many other SBCs which were not.&nbsp;Jessica Miley: Can you say a little bit about your plans for the future with this project? I know that you had said in your submission that you had spoken to one hospital about doing a test. So maybe you can talk a little bit about your plans to scale.Marcel Ochsendorf: Yes, we have talked to one hospital in Germany. It’s the institution I used to work for, so I have some contacts there. Once we finalize our prototype, the hospital has offered to give us some room or an environment to set up and test. This is an opportunity for us if we progress further and are confident that the system is fully working. Then we will have the opportunity to test it there.&nbsp;Jessica Miley: What other resources do you need to do that? What are the challenges ahead, apart from perhaps needing time?Sebastian Kindorf: We are implementing the project following the V-model methodology. The Concept of Operation (CoP) phase is complete, and we are now in the requirements and architecture phase. We are specifying the prototype and final product requirements and concretizing the device implementation. The hardware components for the final system have been determined, ordered, and will undergo step-by-step testing soon.I think we have an edge, and the device has a huge potential, even if we just say we only want to have it in intensive care.&nbsp;Jessica Miley: Final question: What advice would you give to other engineers who are developing novel projects like yours?&nbsp;Marcel Ochsendorf: Be creative. Here in the university context, people are afraid of trying things and wrecking things.&nbsp;Marcel Ochsendorf: You can't get some experience if you don't try it. Okay, this can break but at least you tried. Okay, this breaks. Okay, then it's fine. Then go on to the next iterations. I think this is a very good approach to build rather than overly plan. So, planning is good, but it's not everything!Jessica Miley: I love that approach; just trying something is as important as planning! And what about you, Sebastian? Do you have some advice?Sebastian Kindorf: I agree; if you don't try, you don't get experience. I also think you should make the most of being a student, because you have nothing to lose!Jessica: Thanks guys - this was a great conversation - we really look forward to following your journey with this project.&nbsp;

In response to the OKDo Engineering Challenge, Marcel Ochsendorf and Sebastian Kindorf developed a medical device that uses thermal imaging for remote patient monitoring. Their innovative project won the Wevolver Community Vote. 


Thermal imaging for remote patient monitoring: Winners of the OKdo Engineering Challenge Wevolver Community Vote

As part of the TechBlick (wwww.TechBlick.com) series we invited <a data-hook="linkViewer" href="https://www.linkedin.com/in/wladimirpunt/" id="isPasted" rel="noopener noreferrer" target="_blank">Wladimir Punt</a> from Molex to tell us about how &nbsp;hybrid printed electronics can enhance function and manufacturing of wearable medical sensors.&nbsp; Here you wll learn about the trends, archirectures and challenges. Wladimir and his team at Molex are very well placed in this field, having had the opportunity to develop, prototype, and mass produce many wearable medical sensors over the years. This article was originally published on TechBlick<a href="https://www.techblick.com/post/smart-skin-patches-and-noninvasive-medical-sensing-molex" rel="noopener noreferrer" target="_blank">&nbsp;here.</a>&nbsp;The advance of electronics miniaturization is opening new frontiers in Medtech, including in the field of adhesive skin patches. In the past, a skin patch might contain a single wired sensor. But today&rsquo;s smart skin patches incorporate a broader range of functions. Hybrid printed electronics permit a variety of electronic devices and noninvasive sensors to be affixed to a thin and flexible substrate, enabling designers to integrate sensors, microcontrollers, wireless connectivity and batteries into a capable, durable and connected device.&nbsp;Whether in a clinical or home setting, this enables far more comprehensive patient monitoring. Adding enhanced capabilities to lightweight and flexible skin patches allows patients to go about their day while they (or their healthcare provider) monitor vital signs or activity noninvasively. There is tremendous potential for this flexibility to improve patient monitoring and make it simpler, more comfortable and more accessible.<div data-hook="rcv-block9" type="paragraph"> </div><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"></a><div data-hook="imageViewer" tabindex="0"><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1690284990194-1690284990194.png" alt="" data-pin-media="https://static.wixstatic.com/media/090711_9f48526d064f49abb931769f58299b01~mv2.png/v1/fill/w_1231,h_298,al_c,lg_1,q_90/090711_9f48526d064f49abb931769f58299b01~mv2.png" class="fr-fic fr-dii"></a></div><div data-hook="rcv-block12" type="empty-line"> </div><h3>The Evolving Need for Connected Medical Sensing</h3><div data-hook="rcv-block14" type="empty-line"> </div>The demand for mobile, connected and noninvasive medical sensing capabilities is growing. During the COVID-19 pandemic, the need for hospitals and clinics to monitor patients remotely became clear. This capability did more than allow doctors to track their patients&rsquo; vital signs while maintaining social distancing &mdash; it also helped address hospital overcrowding and assisted in alleviating staffing issues. Smart skin patches have emerged as a lightweight, comfortable and portable method of monitoring patients both inside and outside a healthcare facility.&nbsp;The market for home health monitoring is flourishing as well. With smart skin patches, home users can monitor their heart activity, temperature and muscle health. These devices can be used for monitoring sleep and brainwave activity, making the low profile and light weight nature of smart skin patches especially helpful. Skin patches are increasingly popular for femtech applications such as pregnancy monitoring as well.&nbsp;Smart skin patches all use flexible printed circuit technology and safe skin contacting adhesive, but their design architecture varies depending on the application. Each skin patch design is customized and, depending on the need, can be disposable or reusable. Disposable and one-time-use skin patches have a flexible substrate, usually polyethylene terephthalate (PET), with the electronics affixed directly to the substrate. In reusable patches, the electronics are mounted inside a removable &ldquo;puck&rdquo; housing that mechanically and electrically connects to the substrate. The electronic components are reusable and only the electrodes in contact with the skin are disposable, reducing waste. This can, however, add logistics challenges and costs for the refurbishing process in some cases.<h3>Opportunities and Challenges of Smart Skin Patches</h3><div data-hook="rcv-block21" type="h3"> </div><div data-hook="imageViewer" tabindex="0"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1690284989596-1690284989595.png" alt="" data-pin-media="https://static.wixstatic.com/media/090711_fe0334c255c64ef9b8d8fba7949a06f2~mv2.jpg/v1/fill/w_900,h_661,al_c,q_85/090711_fe0334c255c64ef9b8d8fba7949a06f2~mv2.jpg" class="fr-fic fr-dii" style="width: 578px;"></div><div data-hook="rcv-block24" type="image"> </div>Designers of monitoring systems can leverage a wide range of smart skin patch feature options. The skin patch can include various types of electronic devices. One or more sensors can be fitted, including temperature sensors, chemical sensors, electrodes and even optical sensors. The skin patch can also include a battery, a microcontroller and a radio frequency (RF) antenna to maintain a wireless connection to the network.&nbsp;These are the physical building blocks of the system, and to achieve a specific purpose designers can mix, match and customize them to meet performance targets. Different combinations of sensors and other devices can work with sophisticated software to noninvasively paint a picture of a patient&rsquo;s condition or vital signs.&nbsp;Sounds simple, right? Alas, system reliability requires several different engineering disciplines. For example, material science is vital to ensure the substrate can accommodate the expected wear, yet also provide a secure anchor for the electronic components. The type of conductive paste and hydrogel must meet the system&rsquo;s requirements for manufacturability, shelf life and performance. Electronic components need to operate reliably during the expected lifetime of the product. Robust testing and validation are necessary to ensure product performance and support regulatory compliance.<h3>From Concept to Production</h3>Creating a smart skin patch means assembling multiple puzzle pieces to create a complete system. Collaborating with a company with decades of experience in this field is crucial. At Molex, several engineering disciplines work together to achieve a unified goal:<ul><li>Hybrid printed electronics desig</li><li>Material science</li><li>Wireless connectivity</li><li>Sensor integration</li><li>Prototyping</li><li>Testing and validation</li><li>Production</li><li>Packaging</li></ul>Involving Molex engineers from the earliest stages of the design process helps ensure the product meets performance specifications and manufacturing requirements. In addition to engineering expertise, Molex also offers global manufacturing capabilities to reduce supply chain risks and speed time to market.&nbsp;The need for smart skin patches to improve patient wellness and outcomes is enormous and continues to grow. Our medical expertise and collaborative design approach coupled with our diversified supply chain, high-volume production capabilities and regulatory compliance experience (including ISO 13485 standards) enables Molex to support development of innovative skin patches that improve lives. Explore the benefits of this evolving technology - contact us about customized smart skin patch solutions.<h3>We exhibiting in Berlin on 17-18 OCT 2023. Join us, 78 other exhibitors, 68 presenters and 600+ peers.&nbsp;</h3>Lets RESHAPE Electronics Together, making it Additive, Sustainable, Flexible, and Wearable. <a data-hook="linkViewer" href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank">Explore now www.techblick.com/electronicsreshaped</a><a data-hook="buttonViewer" href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" tabindex="0" target="_blank">Info &amp; Registration</a><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"></a><div data-hook="imageViewer" tabindex="0"><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1690284990355-1690284990355.png" alt="" data-pin-media="https://static.wixstatic.com/media/090711_bfe22a07dc6e40a7996e12e0eda33f46~mv2.jpg/v1/fill/w_1000,h_1000,al_c,q_85/090711_bfe22a07dc6e40a7996e12e0eda33f46~mv2.jpg" class="fr-fic fr-dii"></a></div> <div data-hook="rcv-block50" type="image"> </div>

Status and evolution of intelligent skin patches, enabled by flexible hybrid electronics, going from a single wired sensors to complex wireless multi-function capability. Learn about trends, archirectures and challenges from a manufacturer's point of view to understand how to design for production.

Smart Skin Patches and Noninvasive Medical Sensing

The global medical device contract research organization market was valued at $7.21 billion in 2022 and is expected to expand at a compound annual growth rate of 8.8% from 2023 to 2030. The market growth can be attributed to the growing demand for advanced medical devices, according to <a href="https://www.grandviewresearch.com/industry-analysis/medical-device-contract-research-organization-market-report" target="_blank">an industry research report</a>.To stay ahead of the competition in the rapidly evolving medical device industry, it is crucial to adopt effective design principles. One such principle is &quot;KISS&quot;, Keep It Simple, Stupid. This design philosophy advocates for simplicity and minimal complexity in product design. By adhering to the &quot;KISS&quot; principle, medical device designers can ensure higher levels of user acceptance and interaction. This article explores how to apply &quot;KISS&quot; principles to medical device design, providing valuable insights for staying ahead in this competitive industry.<h3 dir="ltr">1. &nbsp; &nbsp; &nbsp;Reduce the Part Quantities of a Product &nbsp;</h3>For medical product design engineers, reducing the number of components and simplifying product design can significantly reduce workload and minimize design errors. The tasks involved in the development cycle of a medical product component, including concept design, concept discussions, detailed design, CAE analysis, and DFMA checks, as shown in Figure-1, are all demanding tasks. Neglect or errors in any of these stages can have fatal consequences for product quality, cost, and development timeline. Therefore, reducing the number of components and simplifying product design provides visible benefits for engineers, allowing them to allocate more time and energy to improving the quality of product design.<h3 dir="ltr">2. &nbsp; &nbsp; &nbsp;Decrease Color Variations</h3>Color is a powerful tool for communication, classification, and user guidance. It can differentiate important functions (red/yellow) from safe ones (green/blue) and indicate priority levels through shades. Colors can define product sections and remind users of proper usage. They also evoke emotions, with vibrant colors energizing fitness products and warm hues promoting calmness in prenatal settings. In medical product design, color guides users by highlighting buttons and important information on screens. Using color sparingly improves usability, while excessive color can cause confusion. In both software and hardware design, color and contrast lead users to crucial areas in medical devices.<h3 dir="ltr">3. &nbsp; &nbsp; &nbsp;Streamline GUI Design</h3>The increasing use of medical products in home care calls for user-friendly designs that are easy to understand and use correctly. Simplifying the design and making it intuitive through shape can help non-professionals avoid mistakes. Large and single-function buttons, along with strategically used colors, aid in quick identification and access to critical features. In user interface design, minimalism reduces clutter, allowing users to focus on essential information. Fewer choices result in faster decision making, especially in time-sensitive medical situations. Hiding less important features in menus can further streamline the interface.<h3 dir="ltr">4. &nbsp; &nbsp; &nbsp;Simplify the Structure for Easy Cleaning</h3>Medical products must be designed for easy cleaning due to their exposure to bodily fluids, alcohols, acids, reagents, viruses, and bacteria. To achieve this, gaps and crevices in the product&#39;s design should be minimized. Seams can be tightly sealed or covered with overlapping features. Accessible gaps allow for convenient wipe down. Additionally, the design should favor smooth, non-porous surfaces that can be easily cleaned with swabs, sprays, or wipes. Minimalistic shapes with fewer crevices further prevent the accumulation of dirt and contaminants. With our extensive experience in facilitating the development of medical products, we are ready to apply our expertise and manufacturing services for your upcoming project. Our wide range of medical-grade materials and on-demand mechanical parts manufacturing capabilities can streamline the development of medical devices by providing a single manufacturer for all stages, from prototyping to low-volume production to assemblies.

This article explores how to apply "KISS" principles to medical device design, providing valuable insights for staying ahead in this competitive industry.

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