What’s at Stake When Designing Sensor-Enabled Devices

Forj Medical’s Product Development Engineer, Dan Hanson, recently authored an article on micro-sensor integration in Medical Design & Development.

Hanson addressed why sensor integration, not fabrication, is often the true bottleneck in high-stakes device manufacturing, explaining that as microsensors shrink to as small as 0.33 mm they become harder to handle and protect, which can put an entire project at risk if it is not accounted for during the design stage.

Hanson also outlined five considerations for preparing designs for micro-sensor integration, covering placement, protection, material selection, design for manufacturing, and robust testing, emphasizing that addressing them early improves reliability and durability while accelerating time to market and enabling cost-effective production at scale.