Top Engineering Challenges in Designing Next-Gen Wearable Devices

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Top Engineering Challenges in Designing Next-Gen Wearable Devices

The wearable tech industry is leading a wave of innovation, transforming how we monitor, manage, and improve our health. As demand grows for advanced, accurate, and user-friendly devices, engineers face unique challenges in creating solutions that meet modern expectations.

These challenges go beyond aesthetics—they delve into precision, functionality, and integration, all while ensuring these devices remain accessible to the people who need them most. Let’s explore the top engineering hurdles in designing next-gen wearable devices and what they mean for the future of this dynamic industry.

Challenge #1: Power Efficiency and Battery Life

Battery life is a critical factor in the usability of wearable devices. Users expect their devices to run continuously, sometimes for days, without requiring frequent charging. Especially for users who wear their healthtech devices for the primary purpose of health data aggregation or vitals monitoring, it’s critical that they not be required to go through long periods of device inactivity while charging, lest they lose important data tracking.

For engineers, this means designing power-efficient systems that support advanced features like real-time health monitoring and wireless connectivity. Energy harvesting—drawing power from the user’s movements or surroundings—is an exciting area of development, as are wireless charging solutions that eliminate the need for physical connectors.

The ultimate goal is to create wearables that deliver advanced functionality without compromising battery longevity, ensuring the devices are reliable and user-friendly.

Challenge #2: Miniaturisation Without Compromising Performance

Wearables are defined by their ability to blend seamlessly into daily life. When designing best-in-class wearable technology, this means developing smaller, more compact devices that don’t sacrifice functionality or performance.

The challenge lies in packing high-performing components—sensors, processors, and batteries—into lightweight, ergonomic designs. Emerging technologies, such as Novosound’s thin-film ultrasound sensors, enable wearables to achieve this balance. These ultra-thin sensors are not only compact but also capable of delivering highly detailed, real-time physiological data, making them a critical advancement in wearable design.

Advances in flexible circuit boards and lightweight materials also support miniaturisation, enabling devices that are comfortable to wear and still perform to the highest standards. However, finding the right balance between size and capability remains a core challenge in wearable design.

Challenge #3: Data Accuracy and Reliability

In wearable health tech, accuracy isn’t just a feature—it’s a necessity. Users and healthcare providers rely on wearables to deliver precise data for monitoring vital signs and managing chronic conditions.

Traditional sensors often struggle with consistency, leading to inaccuracies that can undermine user trust. Advanced technologies, such as Novosound’s ultrasound-enabled sensors, offer superior precision and reliability. These sensors are helping redefine data quality standards, enabling wearables to capture previously inaccessible metrics, such as detailed blood flow analysis and tissue hydration levels.

Data accuracy remains a cornerstone of engineering innovation, driving the adoption of wearable health tech across industries.

Challenge #4: Seamless Connectivity and Real-Time Processing

Wearable devices don’t operate in isolation—they’re part of a broader ecosystem that includes smartphones, cloud platforms, and healthcare systems, to include more and more health providers relying on data transmitted from user devices to patient records for ongoing review and analysis. Seamless connectivity is essential for transmitting data in real time while maintaining security and reliability.

Low-latency communication protocols like Bluetooth Low Energy (BLE) are addressing some of these challenges, while edge computing is enabling faster processing directly on the device. This reduces dependency on external servers and improves responsiveness.

Ensuring that wearables can integrate smoothly into existing systems while supporting new functionalities is key to their long-term success.

Challenge #5: Durability and Usability

Wearables must withstand the rigours of daily life—sweat, water, impacts—all while maintaining comfort and functionality. Engineers face the challenge of designing devices that are both durable and ergonomic, meeting the demands of a variety of users with diverse lifestyles and needs.

Materials science is playing a vital role here, with innovations in stretchable electronics, waterproof membranes, and lightweight alloys making wearables more versatile. Achieving durability without compromising comfort is a fine balance, but one that is critical to the adoption of wearable devices.

Challenge #6: Privacy and Data Security

As wearable devices collect increasingly sensitive health data, ensuring privacy and security has become a top priority. Engineers must design systems that protect data from breaches and comply with strict regulations such as GDPR and HIPAA.

Encryption, secure data transmission protocols, and on-device processing are some of the methods being used to safeguard user information. However, balancing robust security measures with user convenience remains an ongoing challenge.

Challenge #7: Scalability and Cost Efficiency

To bring next-gen wearables to a broader audience, engineers must find ways to scale production without inflating costs. This involves sourcing affordable materials, streamlining manufacturing processes, and designing devices that are adaptable across use cases.

Modular designs are gaining traction as a way to simplify production while maintaining flexibility. By enabling customisation, these designs can cater to both consumer and medical-grade applications, ensuring that innovation is accessible and impactful.

Looking Ahead: Engineering the Future of Wearables

The future of wearable devices lies in overcoming these engineering challenges and continuing to push the boundaries of what’s possible. Precision sensors, enhanced connectivity, and user-friendly designs are all critical to the success of next-gen wearables.

At Novosound, we’re at the forefront of this revolution, developing advanced sensor technology that addresses these challenges head-on. From ultrasound-enabled wearables to groundbreaking materials, we’re working to make the future of health monitoring more accurate, accessible, and impactful.

Discover how Novosound’s innovations can support your wearable technology projects. Contact us today to learn more.

Want to see our technology in action? Schedule a demo with us at CES 2025 to experience the future of wearable tech first-hand.