Use Case: Digital Twinning & Additive Manufacturing for Wearable Medical Devices

BioSens8 is advancing the future of fertility care through a wearable hormone monitoring device designed to reduce IVF clinic visits and improve patient access. In partnership with MDIC’s Advanced Manufacturing Clearing House (AMCH), the team applied digital twinning and additive manufacturing to optimize the wearable housing for safety, comfort, and manufacturability.

Using COMSOL-based finite element simulations alongside targeted physical testing, BioSens8 evaluated critical design parameters including wall thickness, infill density, adhesive compatibility, print orientation, and thermal performance. This simulation-driven workflow reduced physical prototyping needs by nearly 90% and cut development timelines from months to weeks.

Key outcomes included a final housing configuration featuring 2 mm wall thickness, 15% PLA infill, ergonomic contours, and validated thermal safety across environmental conditions. The approach enabled faster convergence on a manufacturable design while supporting future regulatory readiness through reproducible engineering evidence.

This case study demonstrates how advanced manufacturing tools can compress R&D cycles, reduce costs, and de-risk design decisions in next-generation wearable medical technologies.

Explore the full case study and learn how digital twins are transforming wearable device development.