Electronic medical device including a protective inner shell encasing a battery and electronic components and an outer shell encasing the inner shell

An electronic medical device comprising:

• a printed circuit board assembly comprising a printed circuit board, electronic components mounted to the printed circuit board, a battery mounted to the printed circuit board, and an interface compatible with a physiological characteristic sensor component, wherein the printed circuit board comprises a plurality of protruding sections extending from the printed circuit board;
• a protective inner shell encasing the electronic components and the battery of the printed circuit board assembly, the protective inner shell comprising a first material having low pressure and low temperature molding properties, wherein at least a portion of each protruding section of the plurality of protruding sections is exposed from the protective inner shell;
• and
• an outer shell surrounding at least a portion of the protective inner shell, the outer shell comprising a second material that is different than the first material, wherein the second material comprises a thermoplastic elastomer material or a thermoplastic polyurethane material, and wherein the outer shell includes:
• a first section that encases the portion of each protruding section that is exposed from the protective inner shell and defines a void, and
• a second section that encases the void.