A case study from medical technology
When developing new devices, the question often arises whether a standard enclosure can be used for the electronics. The reason for this consideration is obvious: standard enclosures are readily available, require no additional design effort, and initially incur only low start-up costs. For this reason, they appear particularly attractive in the early project phases. Especially for small production runs or very simple applications, the use of a standard enclosure is therefore a logical choice.
The situation is different for larger quantities, as even medium series sizes of around 1.500 to 2.000 units over the entire project lifecycle generally make the development of a customized housing worthwhile. While tooling costs are initially incurred, this investment quickly pays for itself as series production costs decrease, assembly effort is significantly reduced, and multiple functions can be integrated into a single module.
For example, in the area of wearables or handheld transmitters, the use of standard housings quickly reaches its limits. In these applications, factors such as ergonomics, hygiene, functional integration, and cost-effectiveness determine the success of the product.
Our Case study on the patient wristband with integrated emergency call button This is clearly demonstrated by the example of the customer: The customer initially planned to use a standard housing with additional components. However, in direct comparison, a customized 2K injection-molded housing as technically more sensible and economically significantly more advantageous – especially for the planned quantities in the medium range.
Case Study – Custom Patient Wristband
Initial situation: Standard housing as first consideration
A medical technology company planned to develop a patient wristband with an integrated emergency call button. The electronics—consisting of a circuit board and firmware—were sourced from an external partner. The requirements for the housing were clearly defined:
- high wearing comfort for patients in everyday life,
- Integration of case, electronics, control element and bracelet,
- high hygiene requirements in the clinical environment,
- Economical series production with five-digit quantities over several years.
The customer initially calculated with a Standard housing in combination with a wristband and membrane keypad. The advantage: quick availability without tooling costs. The evaluation revealed that the total costs are comparatively high compared to the benefits offered:
- Case with separate strap: approx. 8 € each,
- additional membrane keypad: approx. 2,50 € per piece,
- Assembly costs for separate components: approx. 1 € per piece,
- Total price per unit: around €11,50, with no added value in terms of ergonomics or design.
It was therefore clear that a standard solution could not meet the requirements for ergonomics, integration and cost-effectiveness.
The challenge
What was sought was a solution that:
- Housing, wristband and emergency button integrated into one assembly, thus significantly reducing assembly effort,
- reduces total life cycle costs,
- the haptics are improved by a defined pressure point,
- ensures high robustness and hygiene,
- and offers scope for different product lines.
Since the client lacked in-house resources for engineering and product design, we acted as an extension of the project. This enabled us to support the project from the initial idea through development and implementation, creating a tailor-made, robust, and cost-effective housing solution.
Solution: Custom 2K injection-molded housing
Together with our team, a tailor-made plastic housing Developed in which the case, wristband, and emergency call button are combined into a robust unit. This allowed the case, flexible wristband, and haptic emergency call button to be combined into a stable assembly.
Molded parts and tools:
- Housing with integrated wristband in 2K injection molding process, with two transparent LED windows for displaying status indicators of the circuit board
- Separate lid with all-round seal (also 2K injection molding) for increased tightness and hygiene
- Additional tool for the bracelet's clasp components
Cost framework:
- Tool costs: €41.000
- Serial costs: €3,84 per piece
By integrating several functions into a single module, the assembly effort could be significantly reduced.
Individual work steps, such as the separate assembly of the case, bracelet, and control element, were completely eliminated. Instead, the customer received the Bracelet already as a fully assembled assembly, which only had to be combined with the circuit board.
This not only significantly shortened assembly times but also reduced the error rate in production. The result was a robust unit with smooth, seamless surfaces that optimally meets the stringent hygiene requirements of a clinical environment.
Economic considerations
Planned sales volumes over 5 years:
- Year 1: 1.000 pieces
- Year 2: 3.000 pieces
- Year 3: 5.000 pieces
- Year 4: 10.000 pieces
- Year 5: 10.000 pieces
Total costs over 5 years:
- Standard solution (€11,50/piece): €333.500
- Customized solution (41.000 € tool + 3,84 €/piece): 152.360 €
- savings: approx. €181.000 after 5 years.
Already from the third year The customized solution was more cost-effective. A five-year period was deliberately chosen for the calculation—a common planning horizon in medical technology.
Advantages of the customized solution
- Cost advantage over the life cycle – significantly lower overall costs despite tool investment.
- Ergonomics & ease of use – haptic emergency call button with clearly defined pressure point.
- Hygiene & Durability – Surfaces with few joints, resistant to disinfectants.
- Reduced assembly effort – pre-assembled module, customer only integrates the circuit board.
- Color variability – Adaptation to corporate design or product lines at no additional cost.
- Brand differentiation – unique design with high recognition value.
Cost advantages and design freedom through customized housing solutions
The Color variability through 2K injection molding allows for easy customization to corporate design or different product lines. The emergency call button can be highlighted in a color, for example, red or green, while the wristband can be manufactured in different colors for different stations or target groups – all without additional painting or printing costs.
Result and conclusion
The customized 2K injection molding solution resulted in savings of approximately €181.000 after five years and continues to offer the customer both functional and ergonomic benefits.
Series production is now running well beyond the originally estimated timeframe. For the customer, this means that the investment has not only fully paid for itself within the first five years, but has also paid for itself many times over—both economically and in terms of quality, reliability, and practicality.
This makes it clear: A standard enclosure is certainly a practical solution for simple or short-term applications. However, as soon as medium production volumes are reached and higher demands are placed on ergonomics, hygiene, and cost-effectiveness, a custom housing clear advantages – technical, functional and, in the long term, also economic.
Good to know – N&H Full-Service Support
Our Full-service support is always included for our customers.
Our experienced engineers accompany you from the initial idea to series production – with:
- Comprehensive consulting from concept development to series development
- Supporting development and design of molded parts, assemblies and complete solutions
- Feasibility studies to secure your product idea
- Optimization suggestions for function, ergonomics and costs
- Advice on material selection
- Development of cost reduction options
- Tests and validations in our in-house laboratory to ensure quality and reliability
In this way, we ensure that you not only receive a technically optimized product, but also have a reliable partner at your side for the entire development and production process.
Standard housing or a customized solution?
We would be happy to discuss with you in a non-binding manner whether a standard enclosure is sufficient for your project or whether a customized solution is the better choice in the long term.
Even if you use a standard housing, we support you with matching protective covers, membrane keypads, cable assembly or other componentsto optimally adapt your product to the application.