News & Resources
June 12, 2020

Pressure Injury Prevention Device Case Study

This pressure injury prevention device has a wearable patient sensor that monitors patient’s motions to help optimize patient repositioning, which can help eliminate pressure ulcers. This is accomplished by notifying nurses as to the patient’s position as well as signaling when it is time to adjust the patient. The device is a disposable worn on the patient’s chest and wirelessly transmits data through a plug-in antenna to computers, tablets or smartphones.


The customer came to Baril with a labor-intensive product design utilizing an off the shelf dressing requiring manual placement of a critical occlusive disk. They took responsibility for the electronics and Baril was tasked with designing a custom cost-effective method of attaching the adhesive to the device and patient. The technical challenge was the placement of an occlusive disk that needed to be accurately placed on a clear substrate, so that the sensor can work through the window.


Baril selected an appropriate clear adhesive material to withstand the patient wearing the device multiple days, including bathing and showering. A rotary press with island placement was the manufacturing process of choice to minimize material waste and automate the accurate placement of the occlusive disk. Perforations were also added to the adhesive film that attaches to the patient to make it easy to remove the wearable, which otherwise could be difficult and painful. The final assembly involves fours layers of material applied in one comprehensive manufacturing process to minimize cost.