How big is the market and at what rate is it growing?
Boerner: Approximately 540 million adults worldwide live with diabetes. Nearly seven million people die each year as a result of this disease. The number of patients is estimated to reach 780 million by 2045, that means the numbers are skyrocketing. Accordingly, many manufacturers of diabetes technology products are currently growing, and it’s not uncommon to see rates of more than ten percent. However, this growth pattern is not the same everywhere in the world: in many regions, the new products are not available to patients for cost reasons. Through our ultrasonic technology, we want to contribute towards safe and efficient manufacturing technology, in order to make the products accessible to more people.
Are there any other applications for ultrasonics in the area of so-called wearables in the pipeline?
Boerner: Ultrasonic welding is also used in insulin pumps and other drug delivery devices. The challenges for manufacturers here are very similar. In addition, there are further applications for ultrasonics, especially for components that come into direct contact with insulin or medication. The joining of plastics with membranes or silicone seals is in high demand. This is done in a process-reliable manner, with traceable process data. Here, too, there is a high level of safety for the patient, because adhesives with sensitive active ingredients do not come into contact with the skin. In addition to the diabetes technology market, we also see similar applications for temperature sensors and for ECG sensors, which are needed to measure heart function. These will revolutionise the medical market.
Does ultrasonic joining technology also contribute towards sustainability?
Stadtmueller: The ultrasonic joining process requires very little energy and no additional joining materials. In contrast, thermal joining processes require heat to be applied to the tool permanently. A large amount of energy is also required to produce adhesives. It is very important for manufacturers and designers to be aware of the options in joining technology, as this is where an important decision for sustainability is made. Boerner: Energy is available everywhere in the world, and no further logistics for consumable materials are required. Ultrasonic technology thereby reduces the CO2footprint of the products. Some of the plastics without additives can be recycled as mono-materials. Of course, recyclates or bioplastics can also be joined using ultrasonics. Herrmann Ultraschall has already conducted many studies with plastics manufacturers in this area.
What role do automation and digitalisation play today?
Stadtmueller: Our customers use almost exclusively automated manufacturing processes. Reproducibility, quality and process data play an increasingly important role here. In medical technology in particular, processes are validated and of crucial importance for the approval of products according to EU regulations or the US-American FDA. These approvals set a very strict framework for manufacturers. Our customers use our process data for each individual weld for process monitoring, but also for traceability. They enable seamless documentation.
The motto of the next K is ‘The Power of Plastics’. What do you think is the power of this material?
Boerner: Plastic is a material with many great properties. The power of plastics in medical technology, for example, lies in their ability to enable innovation while meeting the needs of patients and medical professionals. Plastics are not only a cost-effective, but also a life-saving resource. It is up to us to use this material sensibly and in a resource-efficient way. We are on the right track, with recycled materials and bioplastics already finding their way into many areas. Coupled with intelligent joining processes, we should take advantage of the benefits, and further develop these outstanding technologies.
