Should you choose an off-the-shelf or custom electromagnetic (EM) sensor for your medical device? It’s a critical decision that directly influences market success. The wrong choice risks reliability, manufacturability, and profitability, while the right choice enables you to compete with quality products and cost-effective, scalable production.
The good news? Your decision doesn’t need to be difficult. These four questions will help you decide whether an off-the-shelf or custom EM sensor is right for your medical device.
The Hidden Decision That Defines Product Success
The choice between a custom or off-the-shelf EM sensor can make or break a product. Read this DesignNews article where Intricon explains how your decision impacts product development and market performance.
1. Is Your Device Complex?
Off-the-shelf EM sensors work best for relatively simple devices, but the more complex your device, the less likely an off-the-shelf sensor will integrate cleanly. Even “minor” mismatches in size, geometry, or placement can lead to dangerous performance risks in the field, especially when precision is crucial to device functionality and patient safety.
Custom EM sensors are designed to fit your device’s exact form factor with placement optimized for safe, reliable performance. For example, a wearable heart monitor might require an EM sensor that conforms to a concave housing to maintain skin contact, or a catheter might require a sensor that’s flexible enough to safely navigate the human body. In these highly-complex applications, custom EM sensors can achieve what off-the-shelf sensors cannot.
2. Do You Need IP Control?
Off-the-shelf sensors can limit your ability to protect proprietary software and algorithms. If your sensor plays a key role in product differentiation, a custom design ensures you own the entire system, not just some of the components.
When deciding between off-the-shelf and custom EM sensors, consider the long-term value of protecting both hardware and software innovations. It’s not just about performance – it’s also about protecting your competitive advantage.
3. Do You Require Biocompatibility with High-Fidelity Wireless Signaling?
Many medical devices must meet two demanding requirements: biocompatibility and high-fidelity wireless signaling. Biocompatible devices must use materials that adhere to strict regulatory and durability standards for in-body and on-skin devices – without sacrificing signal integrity.
Off-the-shelf sensors rarely check both boxes, especially when unique and demanding placements in the human body introduce signal, shielding, and durability challenges. Custom EM sensors grant full control over material selection, wireless performance, and longevity, ensuring compliance and connectivity.
4. Do You Need Scalability?
Off-the-shelf sensors introduce uncertainty: supply chain shortages, vendor instability, and sudden price hikes can make scaling unpredictable – or even unfeasible. If demand surges, will your supplier deliver? Will they still be in business?
These disruptions can force costly redesigns mid-program or compel you to switch to a custom EM sensor later – an expensive pivot if your device is already in production. While custom EM sensors may require a move involved development process upfront, they offer greater long-term scalability.
Moreover, owning the design gives you tighter control over production and supply – and while manufacturing partners for custom EM sensors may be more specialized, you’re not locked into a single off-the-shelf part with limited sourcing options.
Next Steps
While off-the-shelf sensors can seem more cost-effective upfront, they often come with hidden costs – from integration headaches to supply chain risks. They might be a good fit for simple devices with standard designs, but custom EM sensors are often the better long-term strategy for complex devices and those that require IP control, biocompatibility with connectivity, and production scalability.
In addition, while many believe the word “custom” signals “expensive,” the reality is that custom EM sensors are often more cost-effective due to seamless integration. In fact, Intricon has helped many of our customers save money by switching from an off-the-shelf to a custom EM sensor.
Not sure which type of sensor is best for your device? Tell us about your project – our experienced engineering team will help you evaluate your options and choose the best solution for your goals.