From Bench to Bedside: Streamlining Mobile Medical Device Design

Major medical procedures have traditionally required patients to travel to the point of care, but new innovations in mobile healthcare technology are transforming the inpatient experience. By bringing medical services directly to the patient, mobile medical devices have become instrumental in reducing patient disruptions, enhancing diagnostic and treatment efficiency, and improving patient outcomes.

“Mobile medical devices reduce cost and improve accessibility of important medical devices like X-ray machines,” said Josh Blackmore, Healthcare Manager, M. Holland. “When X-rays can be taken in a patient’s room instead of a central services area of the hospital, it accelerates the speed and efficiency of treatment to improve patient outcomes. Delivering diagnostics, pharmacy and other treatments to the patient eliminates having to move critically ill patients, reduces congestion in hallways and enables more efficient treatment options.”

Considerations for Optimal Mobile Medical Device Design

Today, solutions such as mobile fluoroscopy, X-ray devices and pharmacy cabinets are redefining the patient experience by streamlining diagnoses and procedures. Developing mobile medical devices like these presents unique challenges that require innovative design solutions. All mobile medical devices must be:

• Lightweight and stable: Devices must be easy to move by one person, and stable enough to support heavy equipment.
• Durable: Materials must be tough enough to withstand impact with walls and have excellent creep performance to maintain functionality.
• Resistant to Disinfection: Surfaces must endure frequent exposure to various chemical disinfectants and cleaners.
• Tamper-Resistant: Unattended medical devices must prevent unauthorized use through methods such as biometric scanning. This is especially important for mobile pharmacy devices where dosage and frequency of medication administration is a key function of device management.
• User-Friendly: Intuitive design, including features like color-coded buttons, simplify operation.

Of course, specific medical devices have their own unique considerations. Imaging compatibility is a critical factor to consider for radiography devices, such as ultrasound and mobile X-ray machines. Making the right material choices is key to ensuring the device remains X-ray permeable for optimal functionality during imaging procedures.

Biocompatibility is essential for components that come into direct contact with patients. These parts must comply with ISO 10993, USP Class VI regulations, or both, and undergo comprehensive testing to ensure they are safe for use in medical environments.

Strategic Approaches to Success

Successful mobile medical device design relies on three key factors: material selection, mold design and the device manufacturing process.

Material Selection is the most crucial element to get right when designing any medical device. Proper material selection ensures safety and functionality and reduces development time. Medical-grade resins are pre-tested for biocompatibility, streamlining the development process for parts that come into direct contact with patients. Medical-grade resins also provide change notifications when their formula changes, enabling manufacturers to promptly assess whether new regulatory testing is required. For components such as bezels, buttons or handpieces, amorphous resins, such as polycarbonate blends, PETG, ABS and amorphous nylon, deliver dimensional precision and maintain color integrity, while materials reinforced by glass and rubber enhance impact strength for mobile equipment. Chemical resistance is non-negotiable, as devices must withstand repeated disinfection. Sourcing practical, readily available resins is essential to maintain seamless production. Engaging material experts early optimizes material choices, paving the way for innovative and reliable designs with excellent supply chain security and cost optimization. Use of non-medical grade resins is possible in structural parts with no patient contact.

Mold Design is a significant factor in enhancing part strength and durability. Molds for mobile medical devices should be created to reduce residual molded-in stresses, especially around screw inserts on housing clam shells. Residual molded-in stress is the stress that remains in a plastic part after it has been molded and cooled. It is caused by factors such as temperature variations, uneven cooling and poor molding practices in general. Residual stress can lead to warping, cracking and other defects in the final product.

“Molded-in stress is often released by disinfectant chemicals causing catastrophic failure, cracking and premature aging,” Josh advises. “Consideration for mold gates number, size and location will help to minimize molded-in stress and improve part longevity.”

The Manufacturing Process also contributes to part strength and durability. Josh recommends reviewing the mold and part cooling parameters to reduce stress, improve cycle time and optimize the molding process. Cycle testing is a crucial step to ensure your device can withstand everyday use and determine its longevity in healthcare environments.

Ensuring Safe and Effective Mobile Medical Devices

Mobile medical devices integrate seamlessly into diverse healthcare settings, ensuring both patients and providers experience greater efficiency in care delivery, regardless of location or infrastructure, but patient safety remains the cornerstone of medical device innovation. By embracing mobility and prioritizing intentional design, medical device manufacturers can revolutionize patient care by helping healthcare providers overcome longstanding logistical challenges.

At M. Holland, we empower our clients to create safe, high-quality medical devices through expert advice on material selection for medical applications, metal-to-plastic conversion and optimal mold design.

Visit our Healthcare market page to learn more about how we transform healthcare through advanced material solutions and support.