The reliance on remote monitoring is growing within modern healthcare. However, clinical decisions are only as reliable as the data on which they are based.
If a device produces inconsistent or inaccurate readings, it can affect patient management and reduce confidence in the technology. While many devices achieve consistent results during testing, maintaining that same level of performance during everyday use is often far more challenging – especially when it comes to long-term wear.
Devices such as continuous ECG, cardiac monitors, CGM patches and wearable biosensors require adhesion to last for 14 days and more. Product developers need to consider how a device will perform throughout its intended wear period, not simply under controlled test conditions.
Sources of Inaccuracy in Remote Monitoring Devices
Real-world use introduces variables that are difficult to replicate during testing phases. Understanding these factors helps manufacturers design devices that continue to perform once they reach the patient.
Motion Artefacts
Movement is one of the most common causes of inaccurate sensor readings. Everyday activities can create slight shifts between the sensor and the skin, introducing noise and disruption into the signal. Even small amounts of movement can affect technologies such as ECG and photoplethysmography (PPG), among others, where stable contact is essential for reliable measurements.
Skin Variability
No two patients present the same skin surface. Hydration levels, elasticity, age and body location all influence how a wearable device performs. Skin condition can also change throughout the wear period, affecting both adhesion and signal quality over time.
Environmental Conditions
External conditions also influence device performance. Temperature changes, perspiration, humidity and UV exposure can alter material behaviour and reduce adhesion. These changes may increase sensor movement, particularly during extended wear.
User Behaviour
Correct application, positioning, wear time and replacement intervals all influence device performance. Comfort is equally important; if a device becomes uncomfortable during use, patients are less likely to complete the intended wear period, reducing the amount of usable data collected.
Wearability vs Performance
Developing a successful remote monitoring device requires a balance between reliable sensor performance and a positive user experience.
Consistent skin contact is essential for accurate data collection, particularly during long-term monitoring. At the same time, wearability extends beyond comfort alone. Skin irritation, limited breathability, poor conformability and excessive fixation can all affect the user experience. This can result in reduced patient compliance and increase the likelihood of premature device removal. The challenge is to maintain stability without compromising wearability.
Miniaturisation adds further complexity. Smaller devices offer practical benefits for patients but provide less surface area for attachment. This increases the importance of material selection, as even small movements can have a greater impact on signal quality.
Design decisions should also consider the needs of different patient groups. A solution that performs well in one application may not provide the same results in another, making application-specific design an important part of product development. Achieving the right balance between performance, skin compatibility and wearability is therefore a key consideration throughout the design process.
The Role of Materials & Adhesives in Data Accuracy
Sensor technology receives significant attention during medical device development, yet the materials surrounding the sensor have a direct influence on overall performance too. Sensors are only as reliable as their physical connection to the patient.
Adhesives help minimise relative movement between the sensor and the skin throughout the intended wear period. Stable fixation reduces movement at the skin interface, helping to minimise signal disturbance and improve measurement consistency, especially for optical, electrical and biochemical sending technologies.
The skin itself presents a challenging surface. It stretches during movement, produces moisture and varies from person to person. Adhesive materials must accommodate these changes while remaining in place, comfortable, breathable and minimising irritation for the patient.
Adhesives also need to work effectively alongside carrier materials, sensors and device housings without affecting performance over time. Long-wear applications place additional demands on every component within the system, such as physiological and environmental stress and material aging.
For this reason, adhesive selection should form part of the overall design process rather than being considered once the device has been developed. Choosing materials that suit the intended application supports both device performance and patient experience.
Designing & Testing Strategies to Improve Accuracy
Improving data accuracy starts during product development. Testing programmes should reflect the conditions that patients are likely to experience during everyday use.
Movement studies, moisture exposure, temperature cycling and extended wear evaluations provide valuable insight into how a device performs outside the laboratory. Human factors testing also helps assess how consistently users can apply and wear the device.
Evaluating adhesive performance throughout the intended wear period helps identify changes in fixation before they affect sensor stability. Skin compatibility testing also provides confidence that devices remain comfortable during prolonged use.
Manufacturing consistency is another important consideration. Validated converting processes and controlled tolerances help to ensure repeatable manufacturing and device performance remains consistent from one production batch to the next.
Accuracy Starts at the Skin Interface
Healthcare providers are placing greater emphasis on continuous monitoring, so remote monitoring is more important than ever. So much so, advances in flexible electronics and connected medical devices are expanding the range of clinical applications available.
As these technologies develop, data quality will remain a defining measure of device performance. Accurate sensors require reliable integration with the materials that hold them in place throughout the wear period.
By combining expertise in medical grade materials, precision converting and adhesive technologies, BDK helps medical device manufacturers develop remote monitoring devices that remain reliable throughout the intended wear period, from early development through to commercial production. Contact us today to get your project started.
