News & Resources
June 12, 2020

Sleep Apnea Diagnostic Device Case Study

This sleep apnea diagnostic device is the world’s lightest and most comfortable disposable home sleep monitor for diagnosing sleep apnea. It records respiratory patterns, pulse oximetry data and estimates sleep time, through a single-use device that is worn on the patient’s forehead with small tubes placed in the nostrils.


The customer came to Baril with crude drawings and a prototype. Baril was responsible for multilayer material selection. One side of the adhesive needed to be firmly attached to the electronics while the other side needed to comfortably stay on the forehead, while being easy to remove.


Baril first selected the ideal materials for this application. Then the next task was to conduct a DFM to support turnkey low volume production for clinical trials. This involved designing and fabricating custom tooling and fixtures, coordinating partners for industrial design, vacuum formed foam and the IFU. Upon completion Baril provided clinical trial units and market test samples that lead to the acquisition of the company by a fortune 500 company.