Encapsulating Wearable Sensors Using a Pre-Mixed Two-Part Epoxy Product How the combined expertise of fluid dispensing leader Nordson EFD and specialty adhesive manufacturer Master Bond ensured an optimal manufacturing process Co-Authors Anthony Buzzerio, Venkat Nandivada and Rohit Ramnath

Case Study: Encapsulating Wearable Sensors Using a Pre-Mixed Two-Part Epoxy Product The growing field of wearable medical technology relies heavily on miniaturized sensors capable of providing accurate and continuous physiological data. Ensuring the long-term reliability and performance of these sensors — often subjected to demanding conditions including physical stress, thermal fluctuations, and exposure to bodily fluids hinges on robust manufacturing processes. A critical aspect of this manufacturing involves the precise application of biocompatible adhesives for encapsulating delicate sensor...

To maintain product integrity, the syringes were shipped in dry ice and stored at –40°C until use. Operators could simply thaw and load the syringes into Nordson's dispensing system, streamlining the workflow and minimizing handling errors. Packaging / Equipment: Dispensing Solutions for Wearable Sensor Manufacturing Nordson EFD offers several fluid dispensing solutions for effectively encapsulating wearable electronics. The company’s broad selection of fluid dispense solutions enables manufacturers to choose the right technology for their unique application needs. Because the Master Bond EP21LSCL-2Med...

The Nordson EFD Ultimus II fluid dispensing solution is an excellent option for manufacturers dispensing epoxies at less than 5 PSI. If larger volume is required (30cc or more), an xQR41V Series needle valve can be an alternative to avoid full-to-empty variation issues. The design of the xQR41V allows for quick fluid change over and easy cleaning of wetted parts at the end of the shift. The needle valve features a patented quick release clasp, enabling fast and easy servicing in the field. In addition, the low level of fluids retained in the fluid body reduces fluid waste, and the reduced form...

Nordson EFD uses a laboratory-focused approach to recommending fluid dispensing technologies — evaluating fluids, substrates, application goals and production needs to provide a consultative approach to selecting the right solution for your needs. The Nordson EFD technical services professionals can assist you with your unique production challenges - click here to learn more. One of the most common challenges in dispensing epoxy adhesives is the presence of air bubbles. To address this, Master Bond implemented rigorous degassing protocols during the packaging process. After mixing the two components...

About the Authors Anthony Buzzerio is an Application/Systems Engineer II at Nordson EFD. He has 4.5 years in the fluid dispensing industry. Buzzerio holds a Bachelor of Science in Engineering from Roger Williams University of Bristol, RI. Venkat Nandivada has over 15 years of experience in analyzing application-oriented issues and provides product solutions for aerospace, electronics, medical, optical and companies. He earned a master’s degree in chemical engineering from Carnegie Mellon University. Rohit Ramnath has 13+ years of experience at Master Bond where he manages new product development...