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54 DESIGN007 MAGAZINE I JULY 2023 Feature Article by Rick Ramos EASTPRINT INC. As wearable electronic devices continue to be more prevalent, it's an ever-greater chal- lenge for companies that manufacture them to keep their competitive edge. It is vitally impor- tant that each device is effective, cost-efficient, and of the highest quality available. To cost-effectively mass produce wearable biosensors, vertical integration of manufac- turing and assembly operations is key. is involves printing conductive inks on flex- ible substrates and successfully performing converting operations (such as lamination of medical-grade hydrocolloids, adhesives, non- woven and foam layers, hydrogel dispensing and/or placement and final packaging) in sur- face-mount technology (SMT) components. Any connections must be made on the "non- patient" side of the patch to ensure patient comfort. We have been successful with 0.010" via print filling in order to have continuity between skin contact and a communication device. Vertical integration for wearable biosensor manufacturing includes: • DFM engineering abilities for tooling, test equipment, and packaging • Screen-printing of silver, silver/silver chlo- ride, carbon, dielectric, and graphic ink • Sheet-fed and roll-to-roll printing • SMT processes with flexible circuits. With screen-printed polyester, etched poly- imide and rigid PCBs may be required for hybrid patches • Screen printed through-holes on flexible substrates Designing and Manufacturing Wearable Biosensors