How a custom 2K injection-molded housing reduced the cost of a patient wristband by over 180,000 euros

A medical technology manufacturer planned to develop a patient wristband with an integrated emergency call button for clinical use. The goal was to develop a robust, hygienic, and cost-effective solution for medium-volume production runs.

Key requirements included high wearing comfort for patients, a reliable emergency call function, and the seamless integration of electronics, housing, control elements, and wristband.

STANDARD HOUSING AS THE INITIAL SOLUTION

At the start of the project, the customer considered using a standard housing in combination with a separate wristband and an additional membrane keypad.

At first glance, this solution seemed attractive, as it incurred no tooling costs and standard components were available at short notice.

However, a detailed analysis quickly revealed the limitations of this approach.

Standard housing including wristband: approx. €8.00 per unit

Membrane keypad: approx. €2.50 per unit

Assembly: approx. €1.00 per unit

Total cost: approx. €11.50 per unit

Despite the comparatively high unit costs, the solution offered neither ergonomic nor functional advantages.

CHALLENGE

The goal was to find a solution that met multiple requirements simultaneously.

Integration of the housing, wristband, and emergency call button into a single assembly.

Reduction of total costs over the product lifecycle.

Improved tactile feedback through a distinct pressure point.

High hygiene and sealing requirements for clinical use.

Robust construction for daily use.

Option for color customization across different product lines.

SOLUTION: CUSTOM-DESIGNED HOUSING USING 2K INJECTION MOLDING

Together with N&H Technology, the customer developed a fully custom housing solution based on a 2K injection molding process.

By integrating multiple functions into a single component, the housing, wristband, and emergency call button were combined into a single assembly. This eliminated numerous individual parts and assembly steps.

DESIGN IMPLEMENTATION

- 2K injection-molded housing with integrated wristband.

- Two transparent LED windows for status indicators.

- Separate cover with a circumferential elastomer seal.

- Additional fastening components for the wristband.

The integrated LED windows allow for the direct display of operational and status information from the electronics. At the same time, the elastomer seal ensures reliable protection against moisture and dirt.

FIVE-YEAR COST-EFFECTIVENESS ANALYSIS

Production volume Year 1: 1,000 units

Production volume Year 2: 3,000 units

Production volume Year 3: 5,000 units

Production volume Year 4: 10,000 units

Production volume Year 5: 10,000 units

Total volume: 29,000 units

Total cost of standard solution: €333,500

Total cost of custom solution: €152,360

Cost savings: €181,140

By the third year, the custom solution was already more cost-effective than the originally planned standard variant.

ADVANTAGES OF THE CUSTOM SOLUTION

1. Lower total costs over the entire product lifecycle.

2. Improved ergonomics thanks to an integrated emergency call button with a defined pressure point.

3. Enhanced hygiene due to a seamless 2K injection-molded design.

4. Reduced assembly effort through the integration of multiple functions into a single assembly.

5. Flexible color design without additional painting or printing processes.

6. Unique product design with high brand recognition.

CONCLUSION

This case study demonstrates that a custom plastic housing in medical technology is often not only the technically superior solution but also the more cost-effective one.

By developing a custom two-component injection-molded housing, the housing, wristband, and emergency call button were combined into a single functional unit. The result was lower production costs, improved usability, and significantly higher product value.

Particularly noteworthy: The project is now in its eighth year of series production. Its long-term use confirms the high quality, robustness, and cost-effectiveness of the developed solution.

YOUR DEVELOPMENT PARTNER FOR CUSTOM ENCLOSURE SOLUTIONS

N&H Technology supports customers from the initial idea through to series production. Our range of services includes feasibility studies, product development, design of plastic parts, tooling concepts, material consulting, cost optimization, and series production.

This results in customized housing solutions that are not only technically impressive but also offer economic advantages throughout the entire product lifecycle.