A plastic surgeon partnered with Pathway MedTech to develop a novel wound closure device designed to improve healing outcomes while simplifying post-procedure care. The concept combined the protective characteristics of gauze with the adhesive functionality of a bandage, and, utilizing the unique properties of silk, created a unique closure solution not available in existing wound care products. 

Pathway supported the client from early concept development through product design, supply chain development, regulatory clearance, and initial commercialization. 

The client had identified an opportunity to improve wound closure technology using a specialized silk-derived material capable of isolating a strong protein component suitable for medical applications. 

While the concept demonstrated strong clinical potential, the project faced several development challenges: 

• Transforming an early-stage concept into a manufacturable device
• Establishing a reliable supply chain for a unique material
• Designing a user-friendly closure system suitable for clinical and consumer use
• Navigating design verification, validation, and regulatory clearance 

The client required a development partner capable of translating the concept into a commercially viable product while managing both technical and operational complexity. 

Pathway worked closely with the client to refine the device concept and guide it through the full development process. 

Concept Development and Prototyping
Pathway initiated an extensive prototyping phase to evaluate different design approaches for the wound closure device. Through this iterative process, the team identified a more practical and manufacturable die-cut geometry similar to conventional adhesive bandages, replacing the client’s original spool-based concept. 

Supply Chain Development
Because the device relied on a specialized silk-derived material, Pathway helped to establish and manage a multi-step supply chain to support production. This included coordinating material processing, adhesive backing application, final device conversion, and preparation for sterilization. 

Product Development and Verification
Pathway developed the complete design package and supported the device through design verification and validation activities to confirm performance, safety, and regulatory compliance. The team also established a validated sterilization process to support commercial distribution. 

With Pathway’s support, the wound closure device successfully achieved market clearance and launched commercially. 

The product quickly gained traction due to its unique material properties and user-friendly design, which support improved healing, strong yet gentle adhesion, and durability during daily activities. 

As demand increased, Pathway continued to support the client by managing product fulfillment and distribution operations, adapting to rapidly growing order volumes and expanding warehousing requirements. 

Today, the device represents a successful example of how innovative materials and thoughtful product design can create meaningful improvements in wound care while achieving strong commercial adoption.