Automation for the Next Generation of Wearable Technology
Wearable medical and lifestyle devices — from biosensor patches to diagnostic monitors — are redefining how people track and manage health. The challenge for innovators is not just product design but scaling manufacturing reliably and efficiently.
We design and build high-precision automation systems and production lines for wearable device assembly, supporting product developers as they move from concept to high-volume manufacturing.
Our expertise combines web converting, precision assembly and advanced process development to industrialise complex wearable devices containing flexible materials, adhesives, sensors and reagents.
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Case Study:
Continuous Glucose Monitoring Device
For a recent wearable sensor project, we developed a sub-second cycle time assembly platform for a needle-free glucose monitoring sensor, transforming flexible 2D materials into complex 3D structures while maintaining strict quality control.
Two years of industrial-scale proof-of-principle work were conducted before full automation build, ensuring predictable cycle times and reliable production performance. We achieved sub-second cycle times with capacity exceeding tens of millions of devices annually, designed to scale as global demand grows.
Automation for Sensor & Patch-Based Wearables
We support automation for a wide range of wearable health and diagnostic devices. From biosensor patches to continuous glucose monitoring devices, needle-free diagnostic sensors to health and fitness wearables - these devices often require high-precision assembly of multi-layer flexible materials, adhesives, and microfluidic components. Our experience in custom and complex assembly automation and web converting technologies can support production of existing and novel wearable health and diagnostics devices.
Web Converting & Flexible Material Assembly
Many wearable devices rely on precision web converting processes to transform flat materials into complex functional products. We have decades of experience in web-converting and flexible material assembly.
Precision Dispensing & Biosensor Integration
Many wearable devices require accurate deposition of biological or chemical materials. We integrate the technologies needed to ensure consistent sensor performance at production scale, including micro-dispensing and enzyme dosing, reagent handling and controlled environments, vision inspection and traceability and precision assembly of sensor components.
View our Capabilities and Solutions pages.
Automation for Wearable Device Assemblies
Beyond patch and sensor manufacturing, we also develop automation systems for the assembly of complete wearable technology devices. Many wearables combine flexible materials, precision plastic components, micro-mechanical parts, adhesives and integrated sensors, requiring highly controlled and repeatable assembly processes. Our automation platforms integrate precision component handling, alignment, bonding, sealing and verification to ensure reliable device performance at production scale. Our expertise in key automation processes means we can support customers with end-to-end automation solutions for wearable products — from material processing and sensor preparation through to full device assembly.
From Concept to Scalable Manufacturing
Wearable products frequently require first-of-their-kind automation, especially when transitioning from laboratory assembly to high-volume production.
We support product developers through the manufacturing process, focusing on understanding and developing processes and industrial proof-of-principle testing. This helps to de-risk at the start of the project and ensure reliable and consistent automation lines.
Our automation systems are engineered to deliver high-speed production with stable cycle times and medical-grade quality and traceability. Engineered to be scalable and flexible, our automation supports your goals from market entry, to when your products evolves and your market demands increase.
Where are you on your Automation Journey?
Wherever you are in your automation journey, we provide the expertise and solutions to help you move forward with confidence. From early-stage validation through to full-scale production, our flexible approach supports everything from proving concepts and processes to delivering fully integrated automation systems.