At Screentec, we pride ourselves on tackling the most complex and demanding projects in the field of wearable medical technology. One of our most advanced products to date is a lightweight, user-friendly wearable device designed for continuous monitoring.
Objectives for the project for design process were focused on creating a product that is lightweight, user-friendly, and comfortable for extended wear. The result is a device that offers an effortless user experience, remains securely in place, and maintains performance for a week — even during regular daily activities.
Production Process
The production process consists of the following key steps:
Printing: We apply precise and reliable printing techniques suitable for flexible sensors.
Material Selection: Materials are carefully selected based on performance, durability, and user comfort to match user demographics.
Roll-to-Roll Process: Our production model includes both in-house manufacturing and selected external suppliers for critical components such as battery, PCBA (Assembled Printed Circuit Board), and plastic casing. To improve scalability and efficiency, we are shifting material preparation, laser cutting, converting, and shaping to roll-to-roll (R2R) production.
Product consists of multiple layers, such as applicator, product layers and liners.
The device is based on a design focused on usability and durability. It combines printed electronics with a traditional PCBA, requiring high precision and strict quality control. The flexible printed structure, PCBA, battery and protective mechanics are integrated to ensure reliable performance. Each unit undergoes thorough assembly, testing, and quality assurance before being carefully packaged and shipped to the customer.
Assembly requires well trained and motivated personnel and continuous process optimization. Each unit is manufactured and documented under ISO 13485 and FDA 21 CFR Part 820 standards to ensure quality, safety, and traceability. The project also includes comprehensive documentation and compliance procedures at every stage of development and production.
The project began as a collaborative research initiative, evolving through multiple iterations to reach its current state. Screentec’s expertise in printed electronics, hybrid integration, and close cooperation with customer engineering teams and research and engineering partners has transformed an innovative concept into a high-performance, production-ready solution that meets the toughest regulatory and technical requirements.
This case highlights Screentec’s capability to take on highly complex integration projects, seamlessly blending printed electronics, advanced materials, and efficient production processes to deliver reliable, user-friendly medical solutions at scale for remote monitoring.
“Working with Screentec was very collaborative. As a customer, I always felt my needs were high priority, and response time to questions was prompt. The Screentec engineering team is very capable and provides sound solutions to technical challenges. In the end, the wearable sensor design achieved our design requirement specifications, and we are satisfied with the outcome.”
– Customer feedback
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