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    CASE STUDY - SILICON VALLEY
    PHARMA PIONEER
    medical device design

    ESCATEC partners with Silicon Valley pharma pioneer to reinvent inhaler tech

    Patients with chronic diseases often struggle with inconsistent or slow-acting medication delivery. A pioneering Silicon Valley pharmaceutical company, known for its breakthrough drug delivery systems, set out to change that - developing a next-generation inhaler that would provide fast, precise, and reliable treatment for a global market.

     

    As a leader in aerosol-based drug delivery, our pharma partner wanted to create a compact, handheld controller paired with disposable medication cartridges. This innovative system would enable precise, efficient, and sustainable treatment for patients with chronic diseases, offering rapid therapeutic effects compared to intravenous alternatives.

     

    "Before partnering with ESCATEC, our prototype was bulky and lacked precise temperature control. Their expertise transformed it into a compact, user-friendly device with significantly improved heating performance."

     

    Head of Product Development, Silicon Valley Pharma Company
    The Challenge

    Despite their expertise in inhalation technology and pharmaceutical formulation, the company lacked the in-house capabilities to develop the mechanical and electronic systems they needed to meet clinical performance and usability goals.

    They wanted a solution that could deliver:

     

    • Precise heating profiles for optimal drug particle size and lung absorption.

    • Reduced waste compared to fully disposable devices.

    • Improved usability for elderly patients or those with motor impairments.

    • Manufacturability at scale, meeting FDA and ISO 13485 standards.

    The Solution

     

    Precision heating control system

     

    ESCATEC developed an advanced heating system capable of delivering precise temperature curves within milliseconds, ensuring optimal drug particle size for deep lung absorption and fast-acting therapeutic effects.

    • High-speed heating control: +/- 3°C tolerance within millisecond bursts.

    • Embedded software integration: Synchronising heating with patient inhalation for maximum efficiency.

    Iterative design for user experience

     

    ESCATEC collaborated closely with the pharma team to optimise the inhaler for patients with acute disease, ensuring intuitive and accessible operation:

    • Cartridge insertion: Designed with tactile feedback for easy use by patients with reduced dexterity.

    • E-Ink display: Provides clear status indicators while consuming minimal power.

    • Screw-free assembly: Simplified from seven parts to four, improving manufacturing efficiency and repairability.

    "Improving clinical performance was one challenge, but ensuring the device remained easy to use was just as crucial. ESCATEC refined every detail to enhance the patient experience."

     

    Senior Engineer, Silicon Valley Pharma Company

     

    Design-for-manufacturing (DfM) & sustainability

     

    ESCATEC optimised the design for scalability, cost efficiency, and environmental sustainability:

    • Reduced PCBA count: Consolidated from three PCBAs to one, minimising complexity and cost.

    • Housing material optimisation: A rugged plastic casing improved durability and ingress protection.

    • Wireless & USB-C charging: Futureproofed power solutions for patient convenience.

    • Reusable core design: Separating electronics from the disposable drug cartridge reduced waste and improved environmental impact.

    "ESCATEC didn’t just solve our technical challenges—they helped us rethink the entire device architecture, making it easier to use and manufacture."

     

    Head of R&D, Silicon Valley Pharma Company

     

    From prototyping to clinical testing

     

    ESCATEC delivered compact, production-ready prototypes, enabling the company to proceed seamlessly into clinical trials and regulatory approval.

    The Results
    inhaler_results_3

    • Faster development timeline: ESCATEC’s early DfX involvement accelerated the transition from concept to clinical trials.

    • Sustainability gains: The reusable controller and optimised materials significantly reduced the device’s environmental footprint.

    • Enhanced user experience: The ergonomic design improved patient usability, especially for those with motor impairments.

    • Manufacturing readiness: The final design met FDA and ISO 13485 standards, ensuring a smooth ramp-up for an initial production phase of 30,000 units.

    "ESCATEC has been an outstanding partner. Their expertise and collaborative approach were instrumental in bringing this technology to life, and we look forward to continuing our work together."

     

    Chief Operating Officer, Silicon Valley Pharma Company

     

    By partnering with ESCATEC, the team successfully revolutionised their inhaler designs, enabling faster, more effective drug delivery. Together, they’re paving the way for a new era of treatment for patients with chronic and debilitating disease.

     

    *The main featured image used in this case study was generated with AI to maintain anonymity.