Streamlining Medical Device Assembly

Faster R&D to Mass Production Using Fluid Dispensing

The rapid journey from inspiration to product launch is crucial in the competitive landscape of medical device manufacturing. At the heart of this expedited process is precision fluid dispensing — a technology that transforms the intricate phases of development into scalable and efficient production.

Partnering early with a leading fluid dispense solution provider like Nordson EFD enables organizations to go from idea to impact faster.

Faster Time-to-Market

Integrating fluid dispensing expertise at the start of medical device development is a proven way to get to market sooner. Early collaboration is key, ensuring that precision fluid management is embedded from research and development to implementing a mass production strategy. Too often a manufacturer selects their fluid first and then tries to make it work for production — thereby introducing challenges by omitting how the fluid will be dispensed to fabricate the product.

When you start with the fluid dispensing first, your organization can accelerate the manufacturing process because you can streamline your research and development (R&D), prototyping, and production processes.

Accelerating the R&D to mass production timetable is advantageous for medical device manufacturers. Your organization gets efficient manufacturing, scalability, quality and flexibility from this approach.

But to get these advantages, manufacturers must prevent problems. There is a clear pathway for success by working in a stepwise fashion through research, design, prototype and production. The benefit to studying your process is that it enables organizations to fix quality issues when the cost to correct them is low.

A smart way to prevent manufacturing problems is to select a fluid dispensing solution that can scale with your organization for mass production. During the prototyping process, prepare for production and manufacturing scalability challenges. For example, using high speed replication processes to produce a batch of devices. This is a beneficial way to use real-world processes to highlight a problem and take appropriate action to change it.

Case Study: Diagnostics Kit Production

A diagnostic kit production case study provides compelling examples that illustrate the transformative power of fluid dispensing technology.

One notable example is the production of point-of-care diagnostic kits. During the COVID-19 pandemic demand soared for these products. By employing scalable jetting valves, manufacturers were able to meet urgent demand with precision and minimal waste.

There were three key challenges to the diagnostic kit production project. First, the manufacturer needed to control their microfluidics. Second, the product required sensitive reagents to operate as intended.

Third, reagents are costly, so low or no waste production is essential. Lastly, the medical assembly manufacturer wanted to obtain repeatable, accurate results using scalable technology.

To meet these challenges, Nordson EFD engineers leveraged their deep skill set in the “art and science” of dispensing reagents. To ensure that the microfluidics and sensitive reagents were handled properly for maximum effectiveness, a gentle dispensing technique was used.

This eliminated scrap, while offering the accuracy and repeatability the manufacturer desired. In addition, the jetting systems used offered the scalable platform the organization was looking for.

Some lessons learned by this medical device assembly organization centered around accelerating the R&D to mass production process. They included combining automating at the lab level with validating the manufacturing process at the process level.

Mastering different dispensing techniques was a valuable strategy, and interfacing with the fluid dispensing solution manufacturer early in the process offered demonstrable time savings. Selecting the fluid used in a small volume and then stepping up to production volumes saved both time and cost.

As the organization defined its process, it validated its findings with R&D.

An important takeaway from this exercise is the importance of reviewing your process to see how automation can benefit your manufacturing and organizational. A keen eye on this process is critical, as standards officials rigorously scrutinize medical devices.

The Path to Full Automation: Practical Strategies for Leaders

A phased approach to adopting automation is an attractive option for many organizations. From manual dispensers to fully automated systems, Nordson EFD offers a logical progression, emphasizing the importance of using compatible components throughout the transition.

Unique to fluid dispensing solution providers, Nordson EFD provides comprehensive solutions, from progressive cavity pumps for lyophilization to automated optical inspection systems, ensuring quality and consistency across the production line.

In order to successfully implement the right technology solution for their production needs, Nordson EFD recommends that organizations “get in front of” their manufacturing process. This is of particular importance if automated production is a goal for your assembly process.

By consulting with our fluid dispensing provider, a manufacturer can ensure that they are using the right equipment for the job while moving towards an automated process as quickly as possible.

Future-proofing the manufacturing process necessitates that some critical production pillars are considered. These production goals include:

• Remote monitoring of the fluid dispensing system
• Collecting and analyzing dispensing data
• Reducing / eliminating scrap and rework
• Automating the process as much as possible

To streamline the pathway to full automation, organizations must make strategic operations and equipment investments that align with their Factory of the Future aspirations.

Some recommended approaches to implementing a stepwise path include these tips for each step:

1. Manual dispensing: Start with manual dispensing, using solutions like the Ultimus I-II.
2. Semi-automated process: As your organization moves toward a more automated process, selecting an automated fluid dispensing robot is necessary. In this case a Tabletop PRO or 3-Axis EV solution is recommended.
3. Fully automated fluid dispensing system: Build a production machine using a PICO Nexµs using the full capabilities from a 3-Axis GVPlus automation systems.

As an organization embraces a fully automated approach, they will need to work with a machine builder or integrator to engineer the systems their process requires. Implementing fluid dispensing is a complex process, but there are simple steps a manufacturer can take to streamline and accelerate the build process with their machine builder.

Nordson EFD recommends starting communications with your fluid dispensing solutions provider and fluid formulator early in the process. It is further recommended that the machine builder and the fluid dispense solution experts are present across the entire process.

That includes machine trials, trials on the fluid dispensing system, and training the machine operators before going into production.

Conclusion: Embracing Advanced Fluid Dispensing for Market Success

Nordson EFD's innovative fluid dispensing solutions not only amplify manufacturing efficiency but also ensure that medical device producers remain competitive. Early engagement, real-world applications, and a strategic path to automation position companies to meet market demands swiftly and effectively. Start transforming your production strategy today by exploring Nordson EFD's fluid dispensing technologies.

For more information on integrating advanced fluid dispensing solutions into your production processes, visit Nordson EFD's website to discover how we can support your journey from R&D to full-scale production. Learn more here.

Learn more by watching the How to Reduce Medical Device Time to Market webinar, click here: View the recording here (in English).

About Mark O'Shea

Mark O'Shea currently serves as the Senior Manager, Business Development, at Nordson EFD. His career at Nordson EFD spans 12 years, including roles in sales, product line management, and operations management. O'Shea holds a Master of Business Administration from the Babson F.W. Olin Graduate School of Business and a Bachelor of Arts in Economics from Union College.