FPC with Silicone Overmolding Manufacturing Solutions

Project Background and Customer Needs

A leading medical device company hopes to develop a new ECG monitoring patch. The patch needs to be highly flexible and comfortable, while being able to accurately collect ECG signals. To achieve this goal, the Medical Company decided to adopt a solution that combines silicone with FPC. However, they had difficulty finding a partner who could implement this complex process. The medical company’s requirements were very strict:

• Material compatibility:The combination of silicone and FPC needs to ensure the compatibility of materials to avoid peeling or poor contact.

• Comfort and durability:The patch needs to be attached to the patient's skin for a long time, so the softness and durability of the material must be guaranteed.

• Signal conduction performance:The FPC part must maintain good conductivity and signal conduction capabilities to ensure the accuracy of ECG data.

• Production process:The production process requires a high degree of precision control to ensure the quality consistency of each patch.

Our Solution

• Material selection:We chose medical-grade high-softness silicone, which not only meets medical standards but also has excellent flexibility and comfort. At the same time, we worked with suppliers to customize a highly conductive FPC to ensure its perfect combination with silicone.

• Process development:We developed a special injection molding process for the combination of silicone and FPC. Through multiple trials and adjustments, we optimized the injection molding parameters to ensure that the silicone can completely cover the FPC without any bubbles or delamination.

• Sample testing:After the initial success, we made a batch of samples and worked with medical companies to conduct rigorous performance tests. These tests include long-term wear tests, signal conduction tests, and biocompatibility tests. The results show that our products perform well in all tests.

• Mass production:Based on the successful sample testing, we further improved the production process and put it into mass production. We have established a strict quality control process, and each batch of products is fully inspected to ensure that every ECG monitoring patch that leaves the factory meets the highest standards.

Results and Conclusion

Through our efforts, the medical company successfully launched a new ECG monitoring patch. This product has not only been well received by doctors and patients, but also achieved excellent sales performance in the market. The leadership of the medical company highly praised our professional ability and cooperative attitude, and expressed their willingness to continue to cooperate with us in the future to develop more innovative medical products.

This successful product development story demonstrates our professional ability and innovative spirit in the silicone + FPC process. As a professional silicone product custom processing manufacturer, we will continue to be committed to providing customers with high-quality and innovative solutions and contribute our strength to the development of the medical industry.