A customer was developing a device for a medical application. For operation, the device needed to be applied directly to the skin and repeated use could reach uncomfortable temperature for patients. To study the device performance, FEA analysis was run at different conditions to determine where thermal conditions most needed to be addressed. Several scenarios were evaluated. In one case the device was modeled with a thermal conductivity epoxy. In another case air was modeled. The analysis concluded that the device was conduction limited and recommended either adding Phase Change Materials or a heat pipe located near the handle to significantly improve heat transfer. Product is now in the market and customer has returned to ACT for next generation thermal management concepts.