Customer Story GlucoModicum
Different types of plastic, sensitive electronics, and short production cycles: To produce a new CGM system for GlucoModicum, the company needed a joining process that could meet these demanding criteria. For this challenging project, Herrmann Ultraschall relied on close collaboration and the development of unique welding tools that enabled the ideal joining process.
The application
The wearable system consists of two components: a rechargeable transmitter and a 1-day biosensor. The biosensor is made of a thin multilayer film supported by a plastic ring.
For the automated production of the biosensor, GlucoModicum needed a joining technology capable of solving two applications within one process chain:
- Attachment of the film to the plastic ring
- Connecting the electrical connection pads to the back of the plastic ring
The connection not only had to be reliable and durable, but also had to protect the sensitive sensor technology and ensure the highest optical quality.
Challenges
- The thin film and the embedded sensors require an extremely gentle joining process that preserves the integrity of the components
- Film and plastic ring consist of different types of plastic, so a conventional ultrasonic welding process was not possible
- As a medical device intended for end users, the design of the connections must meet the highest standards
- High production volumes require an extremely fast joining process
Traditional joining processes such as adhesive bonding were not an option due to limited contact areas, long curing times, and a lack of process safety.
Our solution
- Adjustment of the component design: In collaboration with the product designers at GlucoModicum, the housing was redesigned to include an optimal energy director. It focuses the ultrasonic energy precisely where the connection is to be created and protects the surrounding areas.
- Development of a special sonotrode contour: After several rounds of testing, a unique sonotrode contour was developed that creates the necessary hermetic connection—without loading the sensors.
- Protection of components through a special fixture: A custom-designed fixture made of cast resin securely holds the component in place while dampening vibrations. This prevents visual impairments and protects the integrated electronics.
Customer benefits
“GlucoModicum spent several years developing a miniaturized biosensor which has high sensitivity to glucose. When we began exploring how to manufacture the product, Herrmann Ultraschall’s customer-oriented approach to problem-solving stood out. Rather than asking us to make significant changes to our product, they worked tirelessly to iterate and develop a solution tailored to our needs. With only minimal changes to our original biosensor, they made possible what others had said was impossible.”
Harri Palomäki, Director of Operations at GlucoModicum
Result: A secure connection for the medical wearable
The collaboration with GlucoModicum demonstrates the flexibility and versatility of ultrasonics as a joining technology. It also highlights how crucial an experienced ultrasonic consultant is to the success of a project. With the experience gained from over 2,000 successful applications per year, the necessary modifications to the component and welding tool were implemented, and a process was developed that:
- protects the sensitive electronics
- offers high strength with minimal material thickness
- guarantees perfect appearance
- enables maximum production volumes
Find out more in the complete customer story
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