How Material Innovation is Powering the Next Generation of Medical Wearables

Skin-friendly adhesives, breathable films and how precision converting supports the design of safe, comfortable and effective medical wearables.

The future of healthcare is wearable. From continuous glucose monitors to cardiac patches and smart temperature sensors, medical wearables make care more accessible, personalized and real-time. But with skin as the interface, these devices demand more than just advanced electronics; they require thoughtful material engineering to ensure long-term wear, comfort and safety.

The Skin Matters: Designing for Comfort and Compliance

Skin is a living, breathing organ, and prolonged device contact can easily lead to irritation, moisture buildup and skin trauma without the right materials. That’s why manufacturers turn to specialized components that are:

• Biocompatible and hypoallergenic
• Breathable, allowing moisture and air to pass through
• Flexible enough to move with the body without peeling or tugging
• Strong enough to stay secure through sweat, movement and extended wear

Material Innovation: Building the Ideal Wearable Stack

Sur-Seal supports OEMs and device engineers with converting capabilities for:

• Skin-friendly adhesives: Designed to minimize irritation, these pressure-sensitive adhesives offer secure hold without compromising comfort.
• Breathable films: Polyurethane and other high-MVTR films support moisture wicking while offering a protective barrier.
• Flexible carriers and backings: Nonwovens and thin foams conform to skin contours, enabling longer wear without bulk.
• Pattern-coated materials: Allow for selective adhesion zones and skin visibility or flexibility as needed.

The Role of Precision Converting

Material performance is only half the story. Success lies in how these components are layered, cut and assembled. Sur-Seal’s precision converting services include:

• Multi-layer laminations
• Tight-tolerance die cutting
• Custom configurations for sensors, tabs, ports and contours
• Scalable prototyping-to-production workflows

These capabilities allow OEMs to deliver devices that meet clinical performance without sacrificing user comfort, a win for patients and providers.

As medical wearables become a mainstay in patient care, the materials behind them must be just as innovative as the tech inside. With decades of converting expertise, strategic material sourcing and a commitment to innovation, Sur-Seal helps power the future of healthcare — one comfortable, skin-safe wearable at a time.

Ready to design a more comfortable, compliant and reliable medical wearable? Connect with Sur-Seal’s engineering team to explore material recommendations, rapid prototyping and converting solutions tailored to your application.

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