Relief To Those Living With Tinnitus - From OGM & Medtech Start-Up

When TinniSoothe, a British start-up medical technology company, wanted to make their prototype a reality, they turned to plastic injection moulding provider, OGM, for help. The end result is a Class 1 medical device for the relief of tinnitus in the UK and EU, that looks set to change the landscape for sufferers of this challenging hearing condition.

“As anyone who has had a great product idea will know, putting it into practice is a whole different ball game. My co-founder, Howard Presland, came up with the original idea for TinniSoothe based on his own struggles with tinnitus over many years. The only thing that could distract him from the high-pitched ringing in his ears was the use of background sounds, especially white noise.

However, it was not always practical to switch devices on and off all the time, and it was tiring. So, in conjunction with his brother Lloyd – an electrical engineer - they developed a kitchen table prototype of a wearable white noise device. It was a new type of self-help approach to sound enrichment for those with the condition.” 

- Jez Lawson, one of the co-founders of TinniSoothe.

Following patent approval, the team then worked with product design and software consultancies to perfect the look and efficacy of the device. The result is an innovative product with a range of white noise volume and frequency settings, allowing the wearer to choose the white noise that is right for them as they go about their daily life. With nothing in or around the ears, and up to 72 hours of battery charge, it is a different approach to sound therapy compared to anything else presently on the market.

Thanks to Innovate UK funding, the team was able to get the product certified as a Class 1 medical device. But TinniSoothe needed an experienced plastic injection moulding provider to guide them through the production process. Calum Denver, Key Account Executive at OGM explains further: “When it comes to working with business start-ups, we seek to work with the companies where we can add the most value to their parts, assemblies and processes though innovative solutions. The team at TinniSoothe had a great invention that will help a lot of people, but they had little experience in tooling and injection moulding. We advised that design tweaks in the plastic injection moulding process could help deliver a more robust and cost-effective production solution. Working closely with the team, we recommended a range of possible design amendments, so that the device production process could be industrialised.”

The final Tinnisoothe design was for a 16g wearable device, measuring just 59mm in length, that could be hung from a lanyard or be clipped to clothing. However, it needed to balance being lightweight and easy to operate, yet robust and interchangeable between the lanyard clip and clothing clip. There was also a bedside docking cradle which housed the module at night, and recharged the lithium polymer battery inside.

From a plastic injection moulding point of view, the original prototype looked good, but didn’t mould properly. As both were needed, this created both challenges and opportunities for OGM.

Durability

Following consultation with OGM, iterations of the original prototype were done around the choice of plastic, the overmould for the buttons on the device and the cradle connection solution. As a result, some sections of the original design were thinned down to improve the exterior finish and other areas made stronger to ensure longer device life. TPE was used as an overmould to create more tactile buttons that would be easy to locate if the wearer needed to turn the noise off without looking at the device. ABS polymer was chosen for the front and back of the module and the clipping mechanism, due to its excellent processability, scratch resistance, durability and high impact strength. The design of the clipping mechanism was also adapted slightly to ensure a more snug fit to the lanyard cord, and the grip on it adjusted so that the device could be easily removed and located.

Delivering Cost Efficiencies

OGM also advised on alterations to deliver production cost efficiencies. Traditionally, moulding a device and clipping mechanism such as this requires using one tool per part. However, to keep costs down for TinniSoothe, OGM developed a more bespoke tooling solution that delivered substantial cost savings for the start-up. Thanks to their similar size and shot weight, the six parts were able to be manufactured across three separate tools instead of six. In addition, the click fitment of the clipping mechanism had too much play in the original design. So, instead of using sheet springs or loading mechanisms to resolve the issue, OGM proposed adjustments to the plastic moulding design that eradicated the need for additional springs and assemblies, saving further production expense.

Jez Lawson concludes: “It was important for us to work with a British plastic injection moulding manufacturer who embraced the same values as us: empathy, honesty and originality. We wanted a provider who would be interested in a long-term partnership and who could help us make our vision a reality, in the most cost-effective way possible. Thanks to OGM’s experience in plastic injection moulding, the end result is even better than we could have imagined. Our TinniSoothe device isn’t just lightweight and easy to use, it is also cost-effective to produce and can meet the demands placed on it as a daily wearable.”

 

 

About OGM  

OGM was established in 1962 in Oxford. B E Wightman grew the business over the next 40 years with a dedication to high-quality products and a strong commitment to offering excellent customer service.  Today, these values remain at the heart of everything OGM does. OGM offers total manufacturing solutions for precision injection moulding, from design consultancy and prototype tooling through to high-volume world-class production. OGM customers include international blue-chip organisations, from across a range of sectors, including electronics, general industry, medical and utilities.  

For further information, contact: OGM, Oxford Pioneer Park, Mead Road, Yarnton, Oxfordshire, OX5 1QU. Email [email protected] Web: www.ogm.uk.com

 

About Tinnisoothe Ltd

Tinnisoothe is a British company, with a singular focus on providing seamless tinnitus relief without the need for anything in or around the ears. Designed and manufactured in the UK, its flagship TinniSoothe™ product is certified as a Class 1 medical device.

Tinnitus affects 1 in 10 people on the planet, estimated to be 740m sufferers. TinniSoothe is on an ambitious mission to provide 24/7 tinnitus relief and facilitate long term habituation.

For further information, email [email protected] or go to https://tinnisoothe.com