Maximizing Quality, Minimizing Size in Medical Batteries at WyonMaximizing Quality, Minimizing Size in Medical Batteries at Wyon

In 1997, Marcel Inauen started an illustrious career as an electrical engineer in the R&D department at a Swiss electrical and optical connectivity developer. Since then, Inauen has gone on to hold a number of high-power positions, most notably his current role since 2018 as the CTO of Swiss battery maker Wyon. Here, he’s been a key contributor to the company’s continual development of miniaturized rechargeable lithium-ion solutions for a variety of industries, including medical.

At the upcoming Medical Battery Conference (at MD&M West in Anaheim, CA, Feb. 4–6), Inauen will be presenting on the topic of “How to Meet the Requirements for Miniaturized Rechargeable Medical-Grade Batteries.” Battery Technology had the chance to do a pre-conference interview with Inauen to learn more about his vision for the industry. 

Wyon Chief Technology Officer Marcel Inauen. Credit: Wyon

What are the primary design challenges Wyon faces when creating miniaturized rechargeable batteries for medical devices? 

Wyon Chief Technology Officer Marcel Inauen: The smaller the battery becomes, the more significant the impact of unused volume on the overall volumetric energy density. That’s why we need innovative miniaturization technologies in feedthrough designs and internal cell construction to optimize performance.

Related:UPDATE: 12 Recent Battery-Related Product Recalls

What technological or material advancements have contributed to improving the performance of miniaturized batteries for medical applications?

Inauen: Wyon leverages a unique plastic housing technology that offers multiple performance advantages, including low weight, corrosion resistance, minimal eddy current losses, and the flexibility to integrate additional features into the housing. Regarding energy density, mechanical innovations combined with state-of-the-art electrochemistry contribute significantly to improved performance. Cycle life, on the other hand, benefits from precise cell design, a controlled and complex production process, and the use of high-quality, consistent electrochemical materials.

Could you elaborate on Wyon’s approach to balancing miniaturization with maintaining consistent quality standards across diverse medical device applications?

Inauen: At Wyon, balancing miniaturization with consistent quality standards starts with the choice of rigid housing over a pouch cell. Rigid housings—whether plastic or metal—offer significantly higher precision, along with the performance and safety necessary for medical applications. For implantable devices, titanium enclosures remain the gold standard due to their proven hermeticity. 

Related:Medtronic Issues Explosive McGrath MAC Video Laryngoscope Recall

Wyon has further innovated by developing a proprietary testing method to verify the hermeticity of plastic-housed cells that ensures they meet the same stringent requirements. Additionally, we provide titanium-enclosed cells with an optimized design that maximizes energy density while maintaining uncompromising safety and reliability.

Automated production line at Wyon. Credit: Wyon

How else does Wyon provide long-term reliability and safety for medical-grade batteries?

Inauen: Ensuring the long-term reliability and safety of medical-grade batteries starts with a robust and secure design. As part of our development projects, we conduct comprehensive risk management, including D-FMEA and P-FMEA analyses. Additionally, we carry out full process validation and integrate multiple 100% quality checks into the production setup, such as CTE scanning and hermeticity testing.

Does Wyon collaborate with medical device manufacturers as part of its efforts to meet current and future regulatory standards? 

Inauen: Yes, the process includes early-stage design discussions to align our battery technology with the specific needs of the device and the regulatory landscape. We recognize that regulatory standards vary across countries, and we work with our customers to ensure that all necessary approvals are addressed and tailored to the target markets. By continuously monitoring regulatory updates and incorporating them into our designs and manufacturing processes, we ensure long-term compliance. 

Wyon also employs a robust product lifecycle management (PLM) system to ensure that any changes or adjustments made throughout the lifespan of our batteries align with both customer requirements and regulatory standards. This system allows us to maintain full traceability so that all modifications are documented, reviewed, and implemented with precision.

How important is sustainability in the development of Wyon’s medical-grade batteries? Are there efforts to make these batteries more environmentally friendly? 

Inauen: At Wyon, we recognize the growing importance of sustainability, even in the niche field of medical-grade batteries. While the environmental impact of our small batteries is significantly lower compared to large-scale applications like automotive batteries, we are committed to making a positive contribution where possible. 

One area where we advance sustainability is through the development of rechargeable batteries for applications that were traditionally powered by primary cells. By enabling devices to operate with reusable energy sources, we help reduce the waste generated by disposable batteries, which aligns with broader environmental goals. Additionally, we focus on efficient manufacturing processes and high-quality materials to maximize the lifespan of our batteries. This ensures fewer replacements are needed over time, which minimizes waste and reduces resource consumption.

Information and registration for the Medical Battery Conference at MD&M West is available here.