Simulate to innovate: Why simulation is key to mastering medical device design

As an engineer in the medical device industry, you’re no stranger to the mounting pressures of today’s development landscape. Devices are becoming increasingly complex, regulatory requirements are more stringent than ever and the demand for personalized treatments continues to grow, all while you’re expected to deliver breakthrough innovations faster and more cost-effectively than before.

The good news? Physics-based simulation and building digital twins are transforming how we approach these challenges, offering a powerful solution that aligns perfectly with your expertise in modeling, testing and validation.

Why simulation is essential to achieving medical device designs faster and at lower cost

Slash development costs while accelerating innovation

Remember the last time you had to build multiple physical prototypes to test different design iterations? Those days of expensive trial-and-error are becoming obsolete. By creating physics-based digital twins of your devices, you can:

• Reduce physical prototyping by up to 80% through comprehensive virtual testing
• Generate credible digital evidence that regulatory agencies readily accept
• Explore the entire design space early in development when changes are still cost-effective
• Make physics-informed decisions from day one, minimizing costly late-stage design revisions

Master complex multi-physics challenges with confidence

Medical devices operate at the intersection of multiple engineering disciplines. Whether you’re designing cardiovascular stents that interact with blood flow, orthopedic implants that must withstand complex biomechanical loads or diagnostic equipment with sophisticated thermal management requirements, simulation enables you to:

• Model realistic fluid-structure interactions for devices like heart valves and stents
• Analyze thermal management in implanted devices with embedded electronics
• Simulate complex material behaviors including nitinol shape memory alloys
• Evaluate electromagnetic interference in sensitive diagnostic equipment

Real-world applications across medical device segments

Computational Fluid Dynamics (CFD)

CFD simulation has become indispensable for devices that interact with the fluids that sustain life. From respiratory devices like ventilators and CPAP machines to drug delivery systems and microfluidic diagnostic devices, CFD allows you to:

• Model single and multiphase flows with particle interactions
• Simulate reacting flows for drug delivery applications
• Analyze fluid-structure interactions in cardiovascular devices
• Optimize cooling systems for embedded electronics
• Design more efficient UV-C air purification systems

Mechanical and structural simulation ensuring safety and performance

With seamless CAD associativity and PLM connectivity, mechanical simulation becomes a true enabler of digital transformation. You can:

• Ensure design continuity across iterations with automatic simulation updates
• Integrate E-CAD and M-CAD workflows for comprehensive electro-mechanical analysis
• Perform multibody dynamics analysis for devices with moving parts like hospital beds and surgical robots
• Automate repetitive simulation tasks through templating, allowing you to focus on physics and innovation

System simulation: Design before you build

Before detailed CAD geometries exist, 1D system simulation lets you design and optimize entire systems using validated component libraries. Some examples include:

• Ventilator design with patient lung models for realistic testing scenarios
• Infusion pump optimization across different flow rates and medications
• Surgical robot control system development with Hardware-in-the-Loop testing
• Exoskeleton design balancing power consumption with performance requirements

How B Medical Systems reduced development and testing times

B Medical Systems, a global manufacturer of medical-grade refrigeration devices, faced several challenges in product quality and optimization of engineering time across research, development and testing. The company needed to mitigate long lead times for certain components, which could impact project timelines. Additionally, resource planning for development, testing and quality assurance consumed substantial engineering time, necessitating the implementation of efficient processes to maintain high standards without compromising quality.

Simcenter Amesim played a pivotal role in addressing these challenges by enabling advanced digital simulations that extended the shelf life of temperature-sensitive products and optimized refrigeration designs to safeguard vaccines. The simulation tools, accessible to all engineers, significantly reduced development and testing times by up to 80%, fostering enhanced collaboration and knowledge transfer. The system’s robustness enabled engineers to conduct extensive virtual tests, optimizing component selection even amid supply chain constraints. Read the full case study here.

A promising future for medical device development

Embracing simulation and digital twins in your medical device development process reduces costs, enhances design accuracy and speeds up the journey to market. Adopting these innovative solutions is essential for staying competitive and achieving excellent patient outcomes. Siemens is committed to advancing simulation technologies, empowering you to not only participate in industry evolution but lead it. With simulation, the possibilities are endless and transformative, paving the way for a bright future in medical device development.

Resources

Want to learn more about digital simulation? Check out our resources below:

• White paper: Digital evidence generation: Simulation-driven design for medical devices
• Webinar: How to efficiently assess credibility of simulation-driven medical device regulatory submission
• Case study: Using hemodynamic modeling to improve dialysis patients’ chances of success
• Infographic: Unleash innovation in medical device development with simulation
• Free 30-day trial: Achieve medical device design excellence through simulation

Click here for further information about medical device design.