The Theken Disc with an X-Ray image of the miniaturized electronics module

Artificial spinal disc Incorporates new technological approach
Valtronic Technologies' mission is to contribute to the improvement of the quality of life for individuals through technological innovation. The creation of a miniaturized packaging solution that will be used inside a new artificial spinal disc does just that.

Valtronic Technologies was chosen by Theken Disc to partner on the development of an intelligent artificial spinal disc to replace damaged human discs. The disc is being engineered to restore the natural kinematics and dynamics of spinal motion, as an alternative to spinal fusion. Meanwhile, its embedded electronic package allows it to monitor the patient.

Our objective was to assist with the electronics design and manufacture the microelectronics circuits inside the disc. The disc has embedded microelectronics allowing both the patient and surgeon to manage the postoperative period and maximize the life of the implant.

We designed a miniaturized packaging solution fitting the electronics into a volume of less than two cubic centimeters with more than 80 surface-mount components including crystals, capacitors, and resistors of various sizes and values. It has multiple integrated circuits (ICs) performing data acquisition, processing, storage, data transmission, and power management functions.

Valtronic evaluated three types of flip-chip attachment technologies and a chip-on-board direct-die attach assembly technology to satisfy the space and rigid design requirements of the disc. The result of an extensive study compelled Valtronic to utilize a combination of solutions: the Gold-On-Gold NCA Flip-Chip and Chip-On-Board processes along with surface-mount technology.

Lastly, this project required a complex design that is smaller than most in vivo medical devices but also more energy efficient, reliable, and rugged. Test capabilities were built into the original designs so the need for increased testing would not unnecessarily burden the final size, cost, performance, production throughput, or reliability.

Micropulse designers credit 3D-CSP for its small size

Smallest implantable pulse generator ever made
Can you make it smaller? That is the question that NDI Medical presented to Valtronic Technologies when they approached us about creating the tiniest implantable pulse generator ever made. A device the size of your thumb will help people suffering from disorders such as chronic pain, urinary incontinence, and limb dysfunction.

Implantable neurostimulation units like the micropulse were inspired by the body itself, which has many functions that are electrical in nature. Typically, the devices send programmable electrical pulses via special medical wires to nerves that control pain, muscles and organs. NDI Medical wanted a device that could be customized for the following applications; urinary incontinence management, pain management and muscle stimulation. The device also had to be capable of being controlled by a clinician and the patient with a wireless electronic programmer.

Valtronic Technologies was able to draw on substantial developments in electronic miniaturization over recent years, particularly advances that have made it possible to shrink circuitry. Design innovations have permitted components to be reduced to the size of sand grains, making them so minute that robots must assemble them. Not only are these microscopic circuits more complex, but also they are also more reliable and have stingier energy needs.

In evaluating the packaging options for the die we used 3D-CSP, which offers the most compact assembly. A company effort was put forth to create a desirable solution. Valtronic's Solon facility handled product development for the circuit board, while the company's Romania-based design group worked on the engineering aspects of the Micropulse assignment. Valtronic's headquarters in Switzerland provided a pivotal assist by obtaining a chip for use in the assembly that previously had been available only in packaged form. The combined effort produced a solid solution for NDI and narrowed development time to just four months.

Besides helping many patients sidestep surgery, the units also can diminish or eliminate the need for medication, which is costly and can have troublesome side effects. In addition, implantable neurostimulation devices can help a patient avoid having to undergo long-term and difficult behavior modifications that have been used to deal with some medical issues.

The neurostimulation market is expected to grow exponentially in the next decade. Valtronic Technologies is prepared to continue to advance to meet the needs and demands of the market as they progress.