Tom Hoover, Emerson Automation Solutions01.30.24
As the populations of affluent countries age, there is rising demand for a variety of medical devices. At the same time, advanced sensor and battery technologies make it possible for manufacturers to downsize many devices and make them not only portable but also wearable, offering the possibility of improved quality of life. From smartwatches and fitness trackers to condition monitors to lightweight therapeutic and drug-delivery devices, this technology gives users accurate data that can help them take charge of their own health. Wearables encompass blood pressure monitors, pulse oximeters, and an expanding array of bio- and virus-detecting sensors. Additionally, testing and therapeutic products include continuous blood-glucose monitors and wearable or implantable insulin-delivery devices.
While some devices are designed to be used over long periods of time, many are employed only for hours or days. Given the volume of devices currently available, it is easy to see how they represent a substantial waste stream, presenting costly disposal challenges for manufacturers, health providers, and consumers. Despite being powered and containing valuable components like batteries, specialized circuitry, precious metals, and plastics, only a small number of these devices undergo recovery, reuse or recycling. If closed-loop recycling methods could be used more widely to recover and reuse valuable components and materials, substantial benefits would accrue to the environment and, potentially, to a device manufacturer’s financial performance. Consequently, the industry is focusing on designs that could become part of a circular economy.
Consider the typical structure of a “smart” medical device. It is an assembly of components including electronics, readout, sensors and a power supply, all sealed within a compact, wearable or portable case that is usually made of durable plastic that can be assembled using ultrasonic or laser welding. Wristwatches and wristband monitors, handheld devices, sensors on pendants, finger-clip oximeters, and blood pressure cuffs with compact inflator/readout units all benefit from economical and permanent plastic-bonding technologies that can be pivotal in safeguarding sensitive device components.
However, the permanence of these welds also presents a challenge in manufacturing and recycling. In the event of devices failing performance tests during manufacturing, permanent welds (ultrasonic, laser, etc.) cannot be disassembled without damage to the housing or internal subassemblies. This complicates failure analysis for manufacturers and poses difficulties in recovering valuable internal components. Failed devices, along with their valuable components, often end up as process waste — a loss for manufacturers.
To address this and align with principles of a circular economy, device makers are increasingly focusing on product designs and assembly technologies that facilitate closed-loop recycling. A crucial step is to minimize manufacturing waste by effectively reusing available components.
Responding to this issue, Emerson experts have developed a Branson plastic welding process capable of safely and nondestructively “unwelding” plastics commonly used in medical device bodies and cases. This process, currently undergoing commercial trials, utilizes Emerson’s patented Simultaneous Through-Transmission Infrared (STTIr) laser welding technology in conjunction with product-specific disassembly tooling.
Using this experimental unwelding technology, device makers can successfully open plastic device cases, enabling nondestructive failure analysis and the recovery of valuable functional parts (e.g., wireless transmitter/receiver components, printed circuit boards, electronic subassemblies, displays, batteries) so that can be assembled into new devices. Even the plastics from the disassembled devices are available for reprocessing or recycling. This unwelding process marks a first step for manufacturers seeking closed-loop medical device reprocessing or recycling. It provides a means to optimize product yield, utilize available components and materials efficiently, and minimize waste and disposal costs associated with the manufacturing process.
While these manufacturing benefits are substantial already, the true potential of this unwelding-disassembly technology may lie in the near-future circular economy. Imagine if manufacturers, confronted with high volumes of post-consumer medical devices, could safely and successfully disassemble them, recover high-value components, and reprocess those components for use in new devices. In the case of products like dialysis care devices, which involve biohazardous waste, it could be possible to disassemble, remove and segregate biohazardous components, and then segregate the remaining components — typically 90% or more of the device’s volume — for reprocessing, recycling or disposal.
Both scenarios present almost unlimited potential and could enable large-scale recovery and reprocessing of millions of components and devices. Additionally, the potential for waste and cost reduction is enormous, as the disposal of regulated medical waste costs 50 to 100 times more than the disposal of ordinary waste.
Tom Hoover is the medical business development manager – Americas based out of the Emerson facility in Brookfield, Connecticut. Tom’s vast experience gives him a detailed understanding of the challenges confronting medical device manufacturers and biotech firms. His in-depth medical industry experience in all aspects of product development and regulatory compliance enables him to assist customers in finding the innovative solutions that manufacturers need to thrive.
While some devices are designed to be used over long periods of time, many are employed only for hours or days. Given the volume of devices currently available, it is easy to see how they represent a substantial waste stream, presenting costly disposal challenges for manufacturers, health providers, and consumers. Despite being powered and containing valuable components like batteries, specialized circuitry, precious metals, and plastics, only a small number of these devices undergo recovery, reuse or recycling. If closed-loop recycling methods could be used more widely to recover and reuse valuable components and materials, substantial benefits would accrue to the environment and, potentially, to a device manufacturer’s financial performance. Consequently, the industry is focusing on designs that could become part of a circular economy.
Consider the typical structure of a “smart” medical device. It is an assembly of components including electronics, readout, sensors and a power supply, all sealed within a compact, wearable or portable case that is usually made of durable plastic that can be assembled using ultrasonic or laser welding. Wristwatches and wristband monitors, handheld devices, sensors on pendants, finger-clip oximeters, and blood pressure cuffs with compact inflator/readout units all benefit from economical and permanent plastic-bonding technologies that can be pivotal in safeguarding sensitive device components.
However, the permanence of these welds also presents a challenge in manufacturing and recycling. In the event of devices failing performance tests during manufacturing, permanent welds (ultrasonic, laser, etc.) cannot be disassembled without damage to the housing or internal subassemblies. This complicates failure analysis for manufacturers and poses difficulties in recovering valuable internal components. Failed devices, along with their valuable components, often end up as process waste — a loss for manufacturers.
To address this and align with principles of a circular economy, device makers are increasingly focusing on product designs and assembly technologies that facilitate closed-loop recycling. A crucial step is to minimize manufacturing waste by effectively reusing available components.
Responding to this issue, Emerson experts have developed a Branson plastic welding process capable of safely and nondestructively “unwelding” plastics commonly used in medical device bodies and cases. This process, currently undergoing commercial trials, utilizes Emerson’s patented Simultaneous Through-Transmission Infrared (STTIr) laser welding technology in conjunction with product-specific disassembly tooling.
Using this experimental unwelding technology, device makers can successfully open plastic device cases, enabling nondestructive failure analysis and the recovery of valuable functional parts (e.g., wireless transmitter/receiver components, printed circuit boards, electronic subassemblies, displays, batteries) so that can be assembled into new devices. Even the plastics from the disassembled devices are available for reprocessing or recycling. This unwelding process marks a first step for manufacturers seeking closed-loop medical device reprocessing or recycling. It provides a means to optimize product yield, utilize available components and materials efficiently, and minimize waste and disposal costs associated with the manufacturing process.
While these manufacturing benefits are substantial already, the true potential of this unwelding-disassembly technology may lie in the near-future circular economy. Imagine if manufacturers, confronted with high volumes of post-consumer medical devices, could safely and successfully disassemble them, recover high-value components, and reprocess those components for use in new devices. In the case of products like dialysis care devices, which involve biohazardous waste, it could be possible to disassemble, remove and segregate biohazardous components, and then segregate the remaining components — typically 90% or more of the device’s volume — for reprocessing, recycling or disposal.
Both scenarios present almost unlimited potential and could enable large-scale recovery and reprocessing of millions of components and devices. Additionally, the potential for waste and cost reduction is enormous, as the disposal of regulated medical waste costs 50 to 100 times more than the disposal of ordinary waste.
Tom Hoover is the medical business development manager – Americas based out of the Emerson facility in Brookfield, Connecticut. Tom’s vast experience gives him a detailed understanding of the challenges confronting medical device manufacturers and biotech firms. His in-depth medical industry experience in all aspects of product development and regulatory compliance enables him to assist customers in finding the innovative solutions that manufacturers need to thrive.