The Art of Wearable Medical Devices: 6 Key Considerations
Wearable tech has ushered in a new era of innovation, offering greater convenience, real-time monitoring, and improved engagement. However, behind the sleek exterior of these devices lies a multitude of complex design challenges. Nowhere is this more evident than in the development of wearable medical devices.
Success hinges on harmonizing performance, safety, usability, and aesthetics — all within a form that fits the human body. When done correctly a device can blur the line between medical utility and consumer lifestyle, enabling patients to track vital signs, receive therapy, and interact with their care teams — all without stepping foot into a clinic.
Living With the Device, Not Just Using It
Unlike traditional medical equipment that patients use periodically or only in controlled settings, wearable medical devices become an extension of the user. Whether adhered to the skin, worn on the wrist, integrated into clothing, or embedded into accessories, these products must function continuously and reliably throughout the user’s daily life.
Devices experience heat, sweat, clothing, movement, social interactions, and sometimes even scrutiny. The very nature of continuous wear demands a deep understanding of human anatomy, physiology, psychology, and behavior. From managing friction and skin irritation to addressing emotional stigma and device abandonment, user-centered design is not optional — it’s essential.
At Acorn Product Development, we’ve seen these challenges firsthand through projects like Peerbridge Cor MDx, a next-generation cardiac monitor. Peerbridge approached us to resolve a number of issues including, packaging significantly more electronic functionality into their current design language, improving manufacturability and yield, and creating better ergonomics.
The lessons learned highlight six core considerations that define the art of wearable medical design.
1. Miniaturizing electronics
Minimizing electronics in wearable medical devices is critical and often the first challenge a device faces. Engineers must balance space constraints with the need for reliable performance, integrating complex sensing, power management, and wireless communication systems into an extremely limited footprint. Additionally, reducing the size of batteries while maintaining acceptable runtimes forces trade-offs between power efficiency and functionality.
Our collaboration with Peerbridge offers a clear example of effective space miniaturization. In order to house the sensing technology, wireless charging coil, and batteries into a thin form factor that patients could comfortably wear under their clothes, we had to explore more custom options. Increasing internal space while protecting the exterior design language became a balancing act and resulted in a custom battery that complemented the unique shape of the device. Acorn was able to solve this miniaturization challenge and more without compromising regulatory compliance, durability, or manufacturability.
2. Body Morphology and Fit
People come in all shapes, sizes, and mobility levels. Yet it is often the case that a one-size-fits-all approach is taken when designing medical wearables. To accommodate the widest range of individuals devices must accommodate differences in arm circumference, posture, gait, fat distribution, and even movement patterns.
For example, a heart monitor worn on the chest needs to contour around breast tissue for some users and fit snugly across flat areas for others. We were able to accommodate this on a recent project by exploring a wide range of materials, durometers, and shapes while prototyping. We then put each one through a range of movements meant to represent the maximum range of user motion to determine the ideal solution for comfort and reliability.
3. Material Selection and Skin Interaction
Wearables interface directly with the skin, often for hours or days at a time. As such, biocompatibility, breathability, flexibility, and thermal comfort are critical when selecting the right (CMF) color, material, and finish. Medical-grade silicones and thermoplastics are commonly used, but each application requires a tailored choice of durometer, finish, and chemical resistance.
Adhesive selection poses another significant challenge. For example, a continuous glucose monitor may need to remain affixed to the skin for 10+ days without causing irritation or allergic reaction. The adhesive must balance skin adhesion strength, removal comfort, and resistance to sweat, water, and motion — all without degrading sensor performance. There is no universal adhesive solution; designers often partner with material scientists or dermatological experts to test and validate combinations under various real-world scenarios.
4. User Interface Design and Interaction
The user interface (UI) must be simple, intuitive, and accessible. Whether a user is interacting with a button, screen, app, or relying on haptic feedback, the interaction should feel effortless and predictable. Design teams must account for users with limited dexterity, impaired vision, or cognitive limitations.
This was a central focus during our usability analysis of the Cor MDx device. We found that their devices Interface needed to be usable under clothing, while in motion, and in low-light or even wet environments. The updated design featured a recessed button with improved tactical feedback. This allowed the user's finger to easily locate and press the button without looking. Although a simple addition, it significantly improved users' accuracy and ease of use. This not only eliminated frustration but also gave clinicians more accurate data from users recording cardiac events.
5. Aesthetics, Stigma, and Social Acceptance
In healthcare, performance is paramount — but that doesn’t mean appearance should be ignored. In fact, aesthetic appeal plays a vital role in adherence and emotional comfort. A device that looks overly clinical or draws attention can carry a social stigma that discourages usage, especially among teens or socially active adults. Conversely, a well-designed device can instill pride or even become a conversation piece.
The evolution of eyewear provides a powerful example. Once seen as purely corrective and unfashionable, eyeglasses have transformed into highly personalized accessories. This same shift is occurring in medical wearables, where discreet or stylish industrial design can transform perception and encourage continuous use.
6. Long-Term Wear and Durability
The longer a device is worn the greater the challenge of accurately solving all of the above considerations. Prolonged skin contact can lead to pressure sores, allergic reactions, or device migration if the product is not properly ventilated or fitted. Additionally, adhesive-based devices, reapplication procedures must be foolproof. If a sensor requires exact placement on the skin to function properly, then clear guides, tactile feedback, or visual indicators may be required to support correct usage — even by users without medical training.
Sleep introduces another layer of complexity — devices may be compressed under body weight or twisted during motion. Engineers and designers must simulate these wear scenarios early in development using both physical prototypes and digital modeling tools.
Looking Ahead: The Future of Wearable Medical Design
The next generation of wearable medical devices will be shaped by emerging technologies—flexible electronics, bio-integrated sensors, smart textiles, and AI-driven data interpretation. These Innovations will blur the line between consumer wearables and clinical devices but, the gold standard will be products that combine clinical-grade performance with user centered design.
At Acorn Product Development, we believe the winners in this space will be those who prioritize ergonomics, engineering excellence, and user experience—not as afterthoughts, but as the foundation of the design process. As we continue to help clients like Peerbridge, Seguro, and many more push the boundaries of what’s possible, we remain focused on putting the patient at the center of innovation.
Together we can create wearable medical devices that don’t just monitor health — they enhance lives.