Engineering at the Intersection of Mechanics, Fluids, and Chemistry

Blurring the Lines Between Structure and Circuitry

Product designers and systems engineers are increasingly asked to solve multi-domain challenges within the same structure. This is particularly true in modern medical devices, where single-use catheters, endotracheal tubes, and diagnostic tools must simultaneously support fluid delivery, mechanical actuation, chemical sensing, and electrical monitoring.

Historically, these capabilities have been achieved by layering discrete components: wires for conductivity, swaged markers for imaging, glued sensors for feedback. But these legacy methods come with trade-offs: more parts, more assembly steps, more failure points.

Micropen’s direct-write printing technology offers a new path forward—one that fuses mechanical, fluidic, and electronic functions into a single, seamless structure.

Multifunctional Surfaces, Made Possible by Precision Deposition

At its core, Micropen’s process involves ultra-precise capillary dispensing of conductive, resistive, and dielectric inks onto virtually any substrate. Unlike screen printing or lithography, this is a non-contact method capable of printing fine features on 3D and flexible surfaces, including inflatable structures like balloons.

This makes it possible to:

• Print embedded sensor arrays directly on internal channels
• Route electrical traces alongside fluidic pathways without cross-interference
• Add conductive or radiopaque patterns that move with the substrate during use

In short, direct-write printing transforms the physical structure of the device into the functional circuitry—eliminating the need for add-ons or inserts.

Use Case: Sensorized Single-Use Medical Devices

Consider a catheter designed for diagnostic or therapeutic use. It needs to deliver fluid, monitor pressure, track location, and potentially deliver electrical stimulation. With Micropen technology, these features can be:

• Printed along the inner or outer shaft of the catheter
• Conformally mapped to accommodate bends, tapers, or expanding elements
• Constructed using biocompatible, high-performance inks formulated to meet FDA and ISO 13485 requirements

This approach removes the bulk and rigidity associated with embedded components, enabling devices that are smaller, safer, and easier to manufacture. Importantly, it supports scalability: what starts as a prototype can be translated into full production using the same direct-write process.

Engineering with Fewer Trade-Offs

For device engineers, the value proposition is clear:

• No need to compromise form for function
• Reduced assembly complexity and BOM
• Improved performance in dynamic or soft-tissue environments

Micropen’s five-axis motion systems and vision-based alignment allow for precise deposition even on irregular or changing surfaces. The result is not only functional integration, but also manufacturability at scale—a crucial factor for single-use medical devices.

Questions to Ask When Evaluating Design Pathways

• Can the structure itself become the circuit?
• Are fluid, electrical, and sensing pathways colliding or overlapping?
• Would fewer parts improve reliability or cost?
• If the answer to any of these is yes, it’s time to explore direct-write printing.

Closing Thoughts

As engineering disciplines continue to converge, the boundaries between mechanical, electrical, and chemical systems are dissolving. Micropen’s direct-write technology equips engineers with a way to build at that intersection—where structure is function, and complexity is reduced through precision.

Whether you’re developing next-generation catheters or rethinking disposable diagnostic tools, direct-write printing offers a proven path to integrate fluidics, sensors, and electronics on a single substrate. It’s not just possible. It’s already happening.