Engineering Development

Efficient medical device engineering starts with the right foundation. Sanner applies a comprehensive design-for-manufacturing and assembly (DFMA) approach from the earliest stages, minimizing risks, improving performance in clinical trials, and enabling smoother transitions to full-scale production.

Complex devices demand seamless integration of hardware, firmware, and user interaction. Sanner provides electronics and firmware integration for electronic devices, diagnostic wearables, and instruments, as well as electromechanical drug delivery devices. Our development teams combine technical depth with UI/UX expertise to create intuitive products that deliver sophisticated functionality. We balance technical complexity with user needs to create intuitive experiences that don’t compromise performance.

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Our mechanical engineering team combines a deep understanding of science, engineering principles, precision mechanics, and component selection with the global capabilities of our product development units. We bring together expertise in polymer science, mechanical engineering, and finite element analysis (FEA) to address complex requirements in medical device development.

We simulate injection molding using digital twin models that mirror the current state and simulate future performance. This approach identifies potential design issues early and forms the basis for effective Design for Manufacturing. Mold flow simulations guide tooling decisions and support consistent part quality and reproducibility at scale.

Find out more about Sanner’s pilot and clinical manufacturing capabilities

Advanced device prototyping supports better scale-up by enabling fast evaluation of design options. 3D printed prototypes are especially useful for comparing early concepts and provide the first opportunity after the CAD stage to test a device or component in its real form.

We offer both:

• Fused Filament Fabrication (FFF)
• SLA (stereolithography) printing.

SLA is particularly well-suited for MedTech applications, allowing biocompatible materials to be processed in accordance with ISO 10993 standards.

Using additive-manufactured mold inserts, we can produce test parts in the desired materials early in development, allowing evaluation of material behavior, material flow in the tool, and other process-related properties well before finalizing production tooling.

Device analysis enhances clinical outcomes by identifying risks early, guiding design improvements, and reducing costly delays and rework—supporting faster, more confident decisions throughout development.

To understand, develop, and refine medical devices or drug delivery systems, our multidisciplinary team uses a structured set of device analysis methods:

• Functional maps
• Cause-effect chains
• Sensitivity analyses
• Interaction matrices
• Energy models
• Top-down tests

Sanner uses forensic engineering to perform systematic device analysis that identifies potential design flaws or weaknesses before they become failures in the field. By examining components, materials, functionalities, and manufacturing processes, we help resolve issues found during late-stage testing or after product release. This early intervention helps prevent problems from escalating into recalls or safety events and reinforces the reliability of devices already in use or nearing commercialization.

Successful engineering development ends with the handover of a complete and verified device design to the operational areas for pilot series and commercial manufacturing, supported by a clear cost forecast for series production. When Sanner is engaged solely for design services, the finalized design is returned to the customer at this stage. We can also coordinate the transfer to a customer-designated manufacturing partner when preferred. For clients continuing with Sanner Group, we ensure a smooth transition into production with planning that supports efficient scale-up.

Find out more to Sanner’s pilot and clinical manufacturing capabilities

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