Innovating in Medical Device Manufacturing with the PoNS™ Device

At Aprios, formerly Diversified Plastics, Inc. (DPI), we're proud to partner with industry leaders to tackle complex challenges in medical device manufacturing. One of our key projects involves the Portable Neuromodulation Simulator (PoNS™), an innovative, non-surgical device developed by Helius Medical Technologies, Inc. This device is designed to provide short-term treatment for gait deficits in individuals with multiple sclerosis (MS) and other neurological conditions. PoNS delivers electrical stimulation to the surface of the tongue to support physical therapy programs aimed at improving balance and gait.

Solving Complex Manufacturing Challenges

The PoNS device is not only groundbreaking in its therapeutic capabilities but also in its design complexity. With intricate, close-tolerance plastic components, its manufacturing presented unique challenges. As part of a collaborative effort, we worked closely with Helius Medical Technologies and Keytronic, a contract manufacturer, to refine the manufacturability of key parts, especially the mouthpiece—a critical component in delivering electrical stimulation.

Our expertise in producing high-precision plastic-injection molded parts allowed us to tackle the complexities of the PoNS device. For example, one of the parts in the device undergoes a double-overmolding process, an advanced technique that ensures durability and functionality. By refining processes and working collaboratively, we were able to reduce scrap, improve efficiency, and meet growing production demands for this life-changing product.

The PoNS™ Device Impact

PoNS is currently authorized in the United States for short-term treatment of gait deficit in individuals with mild to moderate MS symptoms, in conjunction with supervised therapeutic exercise programs. Additionally, the device has been approved in Canada and Australia for various neurological treatments, providing hope for millions of individuals suffering from chronic balance and gait issues.

A Team Effort

Bart Bills, Program Manager at Keytronic, highlighted the collaborative effort involved: "DPI’s team has worked diligently with us to improve the manufacturability of these parts. PoNS is such a life-changing product that everyone on the team wants to see it succeed and benefit people around the world."

Download the Case Study

To learn more about the innovative work we did with Helius Medical Technologies on the PoNS device, download the full case study here. You’ll get detailed insights into how Aprios helped bring this transformative medical device to life through advanced manufacturing techniques and collaborative problem-solving.

Ready to see how Aprios can help you with your next project? Contact us today to discuss your manufacturing needs.