One-piece encapsulation
Silicone overmolding covers the PCBA in the cavity; the outer shell and the seal form together, cutting assembly steps and joints.
Silicone overmolding · silicone over PCBA
Silicone Wearable Temperature Monitor
Overmolded PCBA, skin-friendly, continuous tracking
Silicone Overmolding, Continuous Safe Temperature Tracking for Smarter Care
Silicone overmolding wraps the PCBA in one piece, removing the housing and its seams. The soft silicone outer layer sits flat on skin for long-term wear. Mercury-free, replacing glass mercury thermometers.
- Silicone over PCBA
- Mercury-free
- BLE low energy
- Trend curves
Process first
Silicone overmolding: the PCBA goes inside
The difficulty in a temperature monitor is not the sensor, it is the structure. The conventional build is board plus plastic housing plus gasket: many seams, more thickness. Silicone overmolding wraps the board directly, turning three layers into one.
Soft on skin
A thin silicone wall with rounded edges. No hard corners, no foreign-body feel during long wear.
Sweat-resistant, easy to clean
The overmolded seal keeps sweat out, and the surface can be wiped clean between uses.
Repeatable at volume
Wall thickness and encapsulation completeness decide yield, which depends on venting and the process window. See capabilities.
Material and surface feel are project-configurable; selection logic is on materials, and interface validation on testing.
Hardware
A thin build made for long wear
Silicone overmolding keeps the hardware thin, and the build serves one goal: staying on the body for long periods. Nothing is added beyond that.
| Item | Description |
|---|---|
| Form | Thin overmolded patch; silicone overmolding fully encapsulates the PCBA |
| Outer material | Soft skin-friendly silicone, colour and hardness configurable |
| Sensing | Built-in temperature sensor with continuous automatic capture |
| Data link | BLE low-energy Bluetooth, paired at short range |
| Wearing | Adheres close to skin; thin structure suits long-term wear |
| Environment | Mercury-free, replacing glass mercury thermometers and their breakage risk |
Dimensions, runtime and ingress rating are confirmed per project specification; measured data is provided at sampling.
Monitoring system
Continuous temperature, not a single reading
Temperature changes over time. One measurement shows a moment; a curve shows the trend.
Automatic capture
The device logs temperature at set intervals, so patients are not woken for repeated checks.
Trend curves
Scattered readings become a curve: onset, peak and settling are visible at a glance.
High-temperature alerts
A threshold breach raises a notice, so attention comes before the next ward round.
History
Records stay available by time, so a shift handover can look back several days.
One-click report
Export a temperature report for a period, for handover and clinician review.
Bluetooth transfer
BLE carries the data at short range with no extra cabling.
Access and data security
Who sees what is decided by authorisation
Temperature is medical data. Tiered authorisation is not an add-on; it is the first layer of the design.
Tiered authorisation
Patient, family, nurse and doctor each hold a different view scope, mapped to their role.
Controlled access
Only authorised staff can view records; permission changes and revocations take effect immediately.
Encrypted in transit and at rest
Temperature data is encrypted while moving and while stored, reducing exposure risk.
Privacy-aligned design
Designed to medical privacy norms and aligned with common HIPAA and GDPR requirements; specific terms follow the deployment region and institutional agreement.
An aid, never a diagnosis
This is an adjunct monitoring tool. It does not diagnose or treat any condition and does not replace clinical judgement.
What sets it apart
Central dashboard: triage order by temperature risk
Temperature data syncs to the nursing dashboard. The system reorders review priority and triage sequence against risk thresholds, so the febrile or fast-rising patient is seen first.
- Ward view: bed status and temperature in one place
- Automatic ordering: priority suggested by risk level
- Exceptions on top: high or climbing cases surface first
- Decision support: ordering is a prompt, staff decide
Triage logic is configurable; thresholds and priority rules are set by the institution.
Where it fits
Places that need continuous temperature
Not every setting needs continuous monitoring. These share two traits: single readings are not enough, and staffing is limited.
| Setting | Need | What overmolding adds |
|---|---|---|
| Inpatient wards | Night-time swings, handover gaps | A curve replaces scheduled waking; handover has evidence |
| Fever clinics | High volume, fast triage needed | Risk-based ordering on the dashboard eases manual triage |
| Paediatrics | Low cooperation, frequent checks are hard | Thin and skin-friendly, no repeated disturbance |
| Care and rehab homes | Long-term care, tight staffing | Automatic capture and alerts reduce rounds |
| Home monitoring | Family wants remote visibility | Tiered authorisation for family, less anxiety |
| Quarantine and isolation sites | Many people, early detection | One dashboard view, immediate exception notices |
FAQ
Seven questions from procurement and clinical teams
Does overmolding affect accuracy?
No. Sensor position and silicone wall thickness are calculated together at design stage; the overmold is the outer layer and seal, not an obstruction. Sample-stage comparison testing is provided.
Can it be worn continuously?
The outer layer is soft skin-friendly silicone with rounded edges, and the thin build suits long wear. Wear duration and replacement intervals follow institutional policy.
Who can see the data?
Access is role-based: patient, family, nurse and doctor each hold a different scope. Unauthorised users cannot view records.
Does it replace a doctor's diagnosis?
No. It is an adjunct monitoring tool providing continuous temperature and risk prompts. It makes no diagnostic or treatment claim; diagnosis and treatment remain with the clinician.
Why overmold the PCBA instead of using a plastic housing?
A plastic housing needs seams and a gasket, adding thickness and ingress risk. Silicone overmolding wraps the board in one piece: thinner, fewer joints, better for long skin contact.
How is it cleaned and disinfected?
The surface can be wiped clean. Disinfection method and frequency follow the facility's infection-control policy; avoid prolonged soaking and aggressive solvents.
Can data be exported as a report?
Temperature reports and historical curves can be exported by period for handover, charting and clinician review.
Overmolding that sits closer to the body
OEM and ODM supported: structure design for silicone over PCBA, material selection, tooling and volume delivery. Samples and a spec sheet are available.