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Designing Compact and Discrete Wearable Insulin Pumps

The need for increased convenience and comfort is driving demand for smaller, more discreet wearable insulin pump designs. Developing more compact medical devices without sacrificing accuracy, patient safety, reliability or functionality presents a multifaceted engineering challenge. Leading-edge, miniaturized technology from Molex and Phillips Medisize — with advanced signal integrity, precision molding and reliable power management capabilities — affords MedTech engineers with new design strategies that stay ahead of user needs.

Optimizing Wearable Insulin Pump Design


Design engineers face competing constraints when developing wearable insulin pumps that enhance patient acceptance and adherence to therapy. These pumps must be smaller and more discreet to improve user comfort, facilitate easier concealment and provide greater freedom of movement. It is also necessary to maintain high levels of functionality, calculating accurate and consistent insulin delivery for effective diabetes management while meeting stringent safety regulations.

Engineers look to new methods of miniaturization and advanced signal integrity capabilities, to help ensure accurate measurement and delivery of insulin doses that drive patient acceptance and adherence.   Early consideration of regulatory compliance is essential to align the development process with safety standards and ensure a successful wearable insulin pump.

Molex offers specialized expertise and hardware solutions to give design engineers the latest capabilities in miniaturization and space-saving techniques. Recognizing the importance of providing high-quality connectors engineered for superior signal integrity and longer product life, Molex incorporates features like impedance matching and shielding to maintain accuracy. Together with Phillips Medisize, Molex has established rigorous quality management systems compliant with regulatory standards such as ISO 13485, ensuring high-quality design and execution to meet market approval requirements.


Main Electronics and Power


Reducing the size and weight of a wearable insulin pump design improves user comfort and convenience, making the device easier to wear discreetly. This can be achieved in part by employing lighter-weight materials and more compact components that maintain the electrical performance required for core functionality. Molex options for low-profile connectors minimize protrusions from the surface of the pump device, reducing the risk of snagging and discomfort for the wearer, while affording a sleeker, more streamlined profile. 

  Configuration Pitch   Circuits  Actuator Style
FFC / FPC Connectors Wire-to-board 0.20 to 2.00mm

2 to 120  

Front flip, back flip, non-ZIF, slider, flexi-latch, one-touch
  Configuration Pitch Max Derating Current Voltage (Max) Termination Style
Pico-EZmate Connectors  Wire-to-board
1.00, 1.20, 1.80mm

3.0, 5.0A

50V SMT

Flexible Printed Circuits

Flexible Printed Circuits (FPCs) introduce new strategies to achieve ultra-compact insulin pumps through thin, flexible connective circuits that fit into miniaturized spaces and significantly reduce the overall weight of the wearable device.

Printed and Hybrid Electronic Assemblies

Wearable insulin pumps can save significant space with extremely compact circuitry created by combining printed circuit boards (PCBs), flexible circuits or chip-on-board (COB) components that far surpass the density of traditional wired assemblies.

Custom I/O Connectors

The customization of I/O components in wearable insulin pumps optimizes the connector's shape, size and layout to meet specific application requirements. Precise configuration of pins and fine-tuned current-carrying capacities can boost efficiency and power distribution capabilities.

Communications


Electromagnetic interference (EMI) from power supplies or external wireless devices can compromise signal integrity and the reliability of communications in wearable insulin pumps. Design engineers can use proper shielding, grounding and signal routing techniques to help ensure optimal performance and user safety. Proven wearable insulin pump connectors from Molex offer shielding options, such as metalized shells or plates, to help protect against EMI and crosstalk. 

  Configuration Pitch Circuits Current Rating
USB Type-C Connectors Wire-to-board 0.50mm 4 to 24 6.0A
  Configuration Frequency
5G mmWave RF Flex-to-Board Connectors Signal: 2 to 4 
Ground: 4 to 6 
Power: 4 to 0
15 GHz 
25 GHz

Insulin Reservoir and Infusion Set


The structures in wearable insulin pump designs demand precise injection molding and careful assembly processes to effectively perform their intended functions. Quality control measures at every manufacturing step ensure that each component meets the highest standard. This exceptional attention to detail and adherence to safety protocols extends to integrating metal sharps, such as needles or cannulas. Quality management programs developed by Molex and Phillips Medisize specifically address the many production and assembly issues of medical wearables, including tests for patient safety, usability and reliable insulin delivery.

Injection Molding and Assembly

With advanced precision molding capabilities, Design for Manufacturing (DfM) expertise and quality assurance, Phillips Medisize helps clients ensure reliable, safe performance in medical device development.

Sharps

Phillips Medisize brings extensive experience in the integration and assembly of metal sharps, ensuring strict compliance with safety standards and protocols. Collaboration with insulin pump wearable designers builds more efficient production processes and comprehensive quality management systems.

Human Factors


Human factor considerations are a high priority when developing wearable insulin pump designs, often warranting detailed research and testing of user needs, preferences and limitations. Phillips Medisize, a Molex company, has specialized expertise in connected health product development, emphasizing usability and human-centric design — helping ensure wearable insulin pumps and Continuous Glucose Monitors (CGMs) seamlessly integrate.

Connected Health

Phillips Medisize specializes in developing medical device interfaces and integrations for intuitive and comprehensive health management.