[How Luna Labs Creates Breakthrough Solutions for Patients and Warfighters](https://lunalabs.us/biotech-at-the-intersections/)
[How Luna Labs Creates Breakthrough Solutions for Patients and Warfighters](https://lunalabs.us/biotech-at-the-intersections/)
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We sat down with two managers in our Biotech Division, Lauren Costella who heads our biomaterials team, and Kelley Virgilio who leads our bio-devices team, to discuss what makes Luna Labs uniquely positioned to tackle complex biomedical challenges.

Lauren Costella

Kelley Virgilio

Why is Luna Labs uniquely positioned to tackle tough biomedical problems?

Kelley: We’re a unique mix. We are large enough to have expertise across software, firmware, electrical engineering, biology, and chemistry. But we’re small enough to quickly adapt to unique challenges that huge companies might not pursue. We can support products in the $2-5 million annual recurring revenue range that may be opportunities too small for larger companies but are still meaningful to our customers.

Lauren: The biggest thing is the people. We are motivated to solve new problems every day, and everyone has unique expertise that builds upon each other. We’re more innovative because we have people from different backgrounds. A chemist and a materials scientist might help solve a biology problem and bring completely different perspectives and approaches. That cross-pollination leads to breakthrough solutions.

Lauren, focusing on one of the technologies you are developing, can you describe AeroVeil’s sprayable delivery system and how it addresses limitations of current adhesion prevention methods?

Lauren: AeroVeil is a sprayable hydrogel barrier that prevents post-surgical adhesions, which are scar tissues that form between internal tissues and organs after surgery. Current methods use solid films that surgeons place manually, which is difficult over anatomically complex areas, and these products are not approved for use in minimally invasive procedures.

Our sprayable hydrogel conforms to complex anatomical structures and provides coverage where traditional barriers can’t reach. The material forms a protective barrier during the critical healing period, then naturally absorbs.

AeroVeil applicator

AeroVeil spray applicator

We’re addressing a substantial unmet need. Adhesions cause chronic pain, bowel obstructions, and fertility issues, affecting millions of patients annually. There has been a lack of innovation in this space over the last 20 years, and there is potential to make a sizable impact that improves surgical care processes and patient outcomes.

Kelley, what specific need is Proteus addressing, and what engineering obstacles has your team overcome?

Proteus modular hardware and low profile sleeve

Proteus modular hardware platform and low-profile sleeve

Kelley: Proteus provides real-time physiological monitoring for warfighters in combat. We’re tracking vital signs such as heart rate, respiration, and core temperature, where traditional medical monitoring isn’t practical. We are also investigating novel sensors to provide additional vital signs, hydration and hypoxia being two specific examples.

The engineering challenges are significant. The device must be rugged, reliable, and lightweight, while functioning in extreme heat, cold, and moisture. It needs extended battery life and wireless data transmission in challenging environments.

We’ve integrated multiple sensor types into a compact package while maintaining medical-grade accuracy. The data must be available in real-time with sophisticated signal processing to filter out motion and environmental noise, all while lives are on the line. The team has developed custom electronics, innovative power management, and robust packaging, working closely with end users to ensure it works in real combat scenarios.

Where is each technology along its commercial path? What has been the most challenging aspect?

Lauren: AeroVeil is moving toward FDA approval. Our first meeting with the FDA was a huge milestone. The most challenging aspect has been navigating the regulatory pathway while refining the technology. Adhesion prevention is complex, requiring rigorous studies to establish product safety and performance. But hearing excitement from others in the field has been reassuring about the importance of this work.

Kelley: Proteus is in advanced development and testing. We have prototypes and are looking for opportunities to collect data in training environments to further develop our algorithms. The challenge is collecting enough data in representative environments to develop tailored performance and risk indicators for our warfighters. We are also balancing competing requirements such as size, power, durability, accuracy, and cost. Every improvement in one area creates challenges elsewhere. Finding the right trade-offs for real field use requires constant iteration. Working with DOD customers ensures we’re building something that truly meets their needs.

How do the Materials and Biotech divisions collaborate?

Lauren: The collaboration is seamless. Projects often require both materials expertise and understanding of biomechanics or physiology. We don’t work in silos. We approach challenges as a team and figure out together what combination of perspectives, areas of expertise, and solutions will work best.

Kelley: What makes it work is that we’re often doing things that haven’t been done before. It’s not ‘I know the answer, go execute this task.’ It’s ‘let’s figure this out together’ whether you’re a senior engineer or a student intern. The meaningful innovations happen at the intersections where materials science meets electronics or biomechanics meets sensor design.

What keeps you coming to work every day?

Kelley: Working with the team to solve big challenges and seeing innovative solutions develop. We all start with a vision, but it evolves as the team figures out the best direction. I’m constantly amazed at what we accomplish and seeing the impact when customers use our devices in ways that change how their world works.

Lauren: Working with brilliant minds and being challenged daily. I believe in the potential of our projects to make real impact. There are no two identical roles here. Everyone has unique contributions and takes real ownership of the work they’re doing every day.

Looking back on your careers at Luna Labs, what are some of your proudest moments?

Lauren: Our first FDA meeting stands out. Going to the table with them after years of work was a major milestone. It’s been a long development road, but the words of encouragement and excitement that we hear from clinicians and from others in the adhesion prevention space – that reassurance means a lot.

Kelley: The first sale of our Dislotech Joint Reduction Trainer was exciting. We built something everyone said had no market, then had someone want to pay for it during Phase II SBIR. Now our medical simulation training products have been acquired by Integrated Medcraft. Seeing students practice on it before doing real procedures and knowing we were changing outcomes – that’s powerful.

And 3WAVES, our virtual motion system for flight simulations. Seeing the entire team contribute to something that could change the effectiveness of flight simulations. From shoulder simulation to flight simulation to warfighter protection, the breadth shows we can tackle complex problems across very different domains and do it well.

Luna Labs will be showcasing AeroVeil and Proteus at the upcoming CvilleBioHub Device and Tech Expo, demonstrating our continued commitment to developing innovative solutions that address critical healthcare and defense challenges.

Learn more about biotechnologies in Luna Labs’ pipeline.

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