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Inhaler Sensor

Project Overview

Propeller Health, formerly Asthmapolis, tapped Synapse to develop its breakthrough asthma treatment device. Combining medication sensors, mobile applications, and analytics, the Propeller Sensor attaches to existing rescue inhalers to collect data, such as when and where patients experience asthma conditions.
In addition to updating existing designs for optimal reliability and functionality, Synapse offered biocompatible material selection, manufacturing partner selection, statistical tolerance analysis, finite element analysis, Form-Fit-Function tests, first article inspection, and engineering support for the transfer to manufacturing. The final product is a small, lightweight, easy-to-use medical device.

Key Challenges

  • Design for manufacturing
  • Mechanical concerns, such as accidental activation
  • Aesthetics and ergonomics