Design Considerations for Reclosable Fasteners in Wearable Medtech—An Orthopedic Innovators Q&A

By Sean Fenske, Editor-in-Chief
 
Patients who require a support device, such as an orthopedic brace, may already feel vulnerable. The security and assistance provided by such a device can help ensure proper positioning and stability during the healing process. Helping to secure this device into place and facilitate a snug, comfortable fit, the closure and attachment system used on a product such as an orthopedic brace is critical to its success. Most closure and attachment systems for orthopedic devices are made from specialty hook and loop materials that meet the demanding performance requirements of the medical device manufacturer.
 
With this in mind, several representatives from Halco offered their insights on important issues around hook and loop fastening materials and their use in wearable medtech. In the following Q&A, Guy Fussell, general manager, Murray Fussell, marketing manager and sales executive, and Doug Seim, R&D and market development, provide responses to questions regarding working with a medical hook and loop supplier and some of the key considerations that go into the fabrication of hook and loop closure and attachment systems for medical devices.
 
Sean Fenske: What are reclosable fasteners?
 
Guy Fussell: Reclosable fasteners are mechanisms designed to securely attach and detach, or open and close, a product multiple times. Within the broader category of reclosable fasteners, which includes buckled straps, hook and loop, and various types of hardware fasteners, Halco specializes in hook and loop technology, which offers superior versatility, performance, and durability, especially for many types of medical devices.
 

Halco is an ISO 13485 certified manufacturer of medical device components and a specialist in hook and loop fastening systems. We work closely with orthopedic and medical device OEMs in a couple different ways. First, we are a supplier of specialty medical grade hook and loop materials and also on-skin or near-skin adhesive systems for medical device assembly. Second, we provide engineering support and advanced converting services including adhesive lamination, die-cutting, and reclosable fastener parts fabrication. The combination of these specialty fastening materials and our converting services is used to make attachment systems, closure systems, and uniquely crafted hook and loop straps for medical devices.
 
Fenske: Where are reclosable fasteners used in orthopedic devices (i.e., what specific applications)? Where in other medtech segments?
 
Doug Seim: Hook and loop fasteners are widely used in the orthopedic field due to their versatility, adjustability, and ease of use. These fasteners provide a secure closure while allowing for adjustments to fit different body sizes and shapes. Following are some examples of orthopedic products that often utilize hook and loop fasteners:
 

• Braces and Supports: Orthopedic braces, supports, and splints often incorporate hook and loop fasteners to secure the device in place and provide customizable compression and support. Examples include knee braces, wrist supports, ankle braces, and back supports.
• Post-Surgery Garments: After certain orthopedic surgeries, patients may need to wear compression garments or specialized clothing. Hook and loop fasteners can make it easier to put on and adjust these garments without causing discomfort to the surgical site.
• Cervical Collars: Hook and loop fasteners are commonly used in cervical collars, which are used to immobilize and support the neck after injuries or surgeries.
• Shoulder Immobilizers: These devices are used to immobilize and support the shoulder joint after injuries or surgery. Hook and loop fasteners allow for a customizable fit that suits the patient’s needs.
• Orthopedic Taping and Strapping: In some cases, hook and loop fasteners are used in conjunction with adhesive tapes and straps to provide additional support and stabilization to injured joints or muscles.
• Pediatric Orthopedic Devices: Hook and loop fasteners are often used in orthopedic devices designed for children, as they allow for easy adjustments as the child grows.
• Compression Wraps and Bandages: Some compression wraps and bandages used in orthopedics have hook and loop closures, which allow for controlled compression and secure fastening.
• Medical Braces for Conditions like Carpal Tunnel: Orthopedic conditions like carpal tunnel syndrome may require the use of braces or splints that feature hook and loop closures to provide support and alleviate symptoms.
• Orthopedic Prosthetics: Some prosthetic devices, particularly those involving wearable components like straps and padding, may utilize hook and loop fasteners for a comfortable and secure fit.
• Posture Correctors: Posture correction devices often use hook and loop fasteners to encourage proper alignment and provide support for the spine and shoulders.
• Orthopedic Shoes and Sandals: Some orthopedic footwear designs use hook and loop closures to allow users to easily adjust the fit and accommodate foot swelling or different sock thicknesses.

 
Hook and loop fasteners provide a practical solution for orthopedic products by allowing patients, caregivers, and healthcare professionals to easily adjust the fit, compression, and support levels of various devices. Their widespread use in the orthopedic field demonstrates their effectiveness in providing comfort and functionality for patients with a range of musculoskeletal conditions.
 

Hook and loop fasteners are also used in a wide range of medical devices beyond orthopedic products. Following are some examples of other medical devices that utilize hook and loop closures:
 

• Wearable Biosensors: Also known as “wearables,” these devices are often worn either with a strap or an adhesive patch with a hook and loop attachment system
• Ostomy Supplies: Ostomy bags and pouches may feature hook and loop closures to securely attach the pouch to the patient’s body while allowing for easy removal and replacement.
• Blood Pressure Cuffs: Blood pressure cuffs rely on hook and loop to provide a secure closure while the patient’s blood pressure is measured.
• Catheter Securement: Medical catheters, such as urinary catheters or intravenous lines, may use hook and loop fasteners to secure the tubing in place and prevent accidental displacement.
• Surgical Drapes and Gowns: Some surgical drapes and gowns are designed with hook and loop closures to facilitate easy donning and doffing while maintaining a sterile environment.
• Compression Garments: Medical compression garments for conditions like lymphedema or deep vein thrombosis may have hook and loop fasteners to ensure a snug fit and proper compression levels.
• Patient Restraints: In medical settings where patient safety and immobilization are necessary, restraints with hook and loop fasteners can be used to secure patients safely. This is particularly important in patient transport products.
• Tourniquets: Hook and loop is a critical element of windlass tourniquet design, allowing the windlass to be secured while stemming bloodflow in emergency situations.
• Pediatric Medical Devices: Devices designed for pediatric patients, such as monitoring sensors, can use hook and loop fasteners for secure attachment without causing discomfort.
• Neonatal Care Products: Devices used in neonatal care, such as incubator accessories and positioning aids, may use hook and loop fasteners for gentle attachment and adjustment.
• Wound Dressings and Bandages: Some wound dressings and bandages come with hook and loop closures that allow for easy application and secure positioning over wounds.
• Elastic Wraps and Supports: Elastic wraps and supports, like those used for post-surgical recovery or muscle injuries, can have hook and loop fasteners for adjustable compression and support
• X-Ray Radiation Protection Clothing: Hook and loop is used to secure these vests and protect technicians while X-rays are being taken
• Medical Accessories: Various medical accessories like straps, belts, and pouches may incorporate hook and loop closures to secure items like medical tools, equipment, and accessories to the patient or caregiver.

 
These examples highlight the versatility of hook and loop fasteners in the medical field. They provide a convenient and effective way to secure and adjust various medical devices, ensuring patient comfort, safety, and proper functioning of the devices.
 
Fenske: What is the challenge with designing these fasteners into a device? How do you address these?
 
Murray Fussell: Product designers and engineers who design hook and loop closure systems into a device must consider many important performance factors. These include:
 

• Peel strength
• Sheer strength
• Desired cycle life
• The thickness of the closure system
• Its comfort to the patient
• Aesthetics and design
• Environmental exposures
• Adhesives selection
• Fit to the manufacturing process
• Regulatory compliance

 
Halco assists these designers and engineers by providing a deep, specialty portfolio of engineered hook and loop materials that meets the performance and design requirements of a wide variety of medical products. Relevant technologies provided by Halco include:
 

• Halco unnapped loop
• Halco double-sided loop
• Halco C-Fold loop strapping
• Halco soft woven hook
• Halco plastic molded hook, types 1-4
• Medical molded hook
• Medical knit loop tape

 
We also provide engineering support, converting, die-cutting, customized fabrication services, and advanced adhesives to help our customers design the best performing closure system for their product. Halco is trusted by medical device manufacturers and is an ISO 13485 certified fabricator of hook and loop fastener components. We fabricate a lot of custom hook and loop straps and hooked tabs for the medical industry, both for orthopedic manufacturers and the rapidly growing “wearables” market.
 
Fenske: As more healthcare therapies are happening “on the go” or in the home, does that make this component a more critical consideration than with hospital-based devices?
 
D. Seim: Wearable medical devices (also known as “wearables”) are one of the highest growth areas of the medical device market, enabling continuous monitoring of patient health data. Halco is a supplier of medical grade hook and loop fastening materials, pressure sensitive medical adhesives, and custom straps and patches made with state-of-the-art converting services that help make these clinical grade wearables possible. Hook and loop closure systems are a critical consideration for both high-tech “wearables” and more traditional orthopedic and regular medical products. What makes the “wearables” market a little different is its frequent need for on-skin, medical grade materials that meet sterilization requirements. Halco is a Platinum level converter for 3M Medical Materials & Technologies and is one of the largest suppliers of these materials in North America.
 
Fenske: Are there advantages that can be realized from designing the fastener in early? This seems like it could be a component afterthought among designers? Is that often the case?
 
G. Fussell: For most experienced designers of orthopedic and other medical device products that use hook and loop closure systems, they realize how fundamentally important that component is to the overall performance of their product. But there are several occasions when a manufacturer will wait until late in the manufacturing or sourcing stages of the project to start working on the fastening system.
 
The benefit of contacting Halco early in the process is we can offer more customized and innovative solutions that enhance the performance or design of the customer’s product. This includes custom colors, hook styles, die-cutting, custom printing, specialty backings, and webbing materials that enhance comfort and aesthetics, custom strap designs, and many other options. We will also educate the customer on a wide variety of specialty hook and loop products they otherwise would not have been aware of. These specialty products open options and can enhance design and product functionality. Finally, we also provide services like custom adhesive lamination and die-cutting of custom shapes that further enhance performance and productivity. A good example of this is many orthopedic braces use hook and loop straps to secure the brace. The strap often requires a tab at the end of the strap with a hook on it that attaches to the loop material strap. Halco will die-cut these tabs to speed the customer’s manufacturing productivity. When customers contact us early in the project, there simply are more possibilities to improve the customer’s product design and manufacturing process.
 
Fenske: What considerations do device manufacturers overlook when it comes to the fastener? What’s misunderstood about them, their value, and/or the job they perform?
 
D. Seim: When an engineer or product designer is new to hook and loop closure systems, they may only be aware of regular nylon woven hook and loop. However, there are a wide range of other specialty hook and loop product solutions, such as plastic molded hook and self-engaging hook and loop materials that provide unique solutions. Part of Halco’s mission is to educate the customer on a full range of product and material possibilities. The range of possibilities is much wider than what is often assumed or understood.
 
Another response we often hear is “I want a hook and loop combination with high engagement strength and long cycle life.” The reality in most hook and loop combinations is there is an inverse relationship between the engagement strength and cycle life. The sturdiest, most rigid hooks (often a plastic molded hook product) have high engagement strength but lower cycle life. Tighter loop materials have lower cycle life than a looser loop or an unnapped loop. The art and science of designing the best performing closure system is selecting the right pairing for the requirements of the application. So it’s best to work with Halco early to find the right balance of engagement strength and cycle life, while also meeting other performance and design requirements.
 
Fenske: Do you have any additional comments you’d like to share based on any of the topics we discussed or something you’d like to tell orthopedic device manufacturers?
 
G. Fussell: Consistent with what we’ve already said, it’s best to involve Halco early, not just in the manufacturing or sourcing stage, but we also strongly suggest you involve us in product design. We can make you aware of a wide range of specialty engineered fastening materials that can enhance the performance and functionality of your design. We can also do things that you might not expect, like integrating a hook and loop fastener with a high-performance foam material, an elastic, or a plastic part. So, we’re more than a very good supplier of engineered hook and loop solutions; we’re also a design and manufacturing partner focused on your needs and success.
 
It all starts with a conversation with one of our representatives. Tell us about your project and let’s get started with a free evaluation of some of our engineered fastening materials.
 
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