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Design Change Notification Guide

Understanding when design changes require notification to regulatory bodies (FDA, EU Notified Bodies) and test labs (NRTL/CB) is critical for compliance. Early decisions during design can prevent costly re-submissions later.

FDA

510(k), PMA Supp

Test Labs

UL, TÜV, CSA

EU MDR

Notified Body

21 CFR 820.30(i)Design Controls Guide

Why Design Change Planning Matters

Common Costly Mistakes

  • ✗Implementing changes before regulatory assessment
  • ✗Not tracking cumulative changes (death by 1000 cuts)
  • ✗Assuming test lab certification covers all changes
  • ✗Missing EU MDR significant change notification

Potential Consequences

  • !FDA Warning Letters and 483 observations
  • !Loss of CE marking and EU market access
  • !Product recalls and market withdrawals
  • !Extended timeline for new product introductions

Best Practices for Design Changes

Early Planning

  • • Assess notification requirements before design
  • • Consider long-term product roadmap
  • • Factor in regulatory timeline to project plans
  • • Build flexibility for component changes

Documentation

  • • Maintain change history log
  • • Document risk analysis for each change
  • • Keep Letters to File organized
  • • Track cumulative changes

Communication

  • • Proactive notification to test labs
  • • Regular NB communication (EU)
  • • Cross-functional change review
  • • Supplier change notification agreements

21 CFR 820.30(i) - Design Changes

"Each manufacturer shall establish and maintain procedures for the identification, documentation, validation or where appropriate verification, review, and approval of design changes before their implementation."

Required Elements:

  • • Identification of the change
  • • Documentation of the change
  • • Verification or validation of the change
  • • Review of the change impact
  • • Approval before implementation

Key Considerations:

  • • Impact on design outputs
  • • Impact on finished device
  • • Regulatory submission impact
  • • Effect on validated processes
  • • DMR and DHF updates

Test Lab (NRTL/CB) Notification Guide

When your product has third-party safety certifications (UL, TÜV, CSA, etc.), many changes require notification even if no FDA submission is needed.

Typically Require Notification

  • • Any electrical component changes
  • • Enclosure material or dimensions
  • • Power supply changes
  • • PCB layout modifications
  • • Insulation system changes
  • • Manufacturing location changes

May Not Require Notification

  • • Cosmetic changes (colors, labels)
  • • Equivalent component substitutions*
  • • Software changes (non-safety)*
  • • Packaging changes (non-sterile barrier)

*Check your specific certification for requirements

EU MDR - Significant Changes (MDCG 2020-3)

Under EU MDR, "significant changes" to certified devices require Notified Body assessment before implementation. The MDCG 2020-3 guidance provides criteria for determining significance.

Significant Changes Include:

  • • Changes to intended purpose
  • • New or modified indications
  • • Changes affecting safety/performance
  • • Design changes to critical components
  • • New manufacturing sites (for critical processes)
  • • Changes to sterilization method
  • • Software changes affecting safety
  • • Material changes (biocompatibility)

Important: For legacy devices transitioning under MDR Article 120, you must notify your NB of all significant changes. Failure to do so can result in loss of market authorization.

Related Resources

FMEA Calculator

Risk analysis for design changes

Regulatory Pathway Tool

Determine submission requirements

Design Controls Guide

ISO 13485 7.3 implementation

Design Change Notification Guide

Determine when to notify test labs and regulatory bodies about design changes

Design Change Decision Tree

DESIGN CHANGEAffectsSafety?YESChangesIntended Use?YESNEW 510(k)RequiredNOEVALUATE SEMay need 510(k)NOMajorChange?YESEVALUATESpecial 510(k)?NOLETTER TOFILECERTIFICATION BODY (NRTL/CB)Notify for electrical/safety changesMay require review or retestingEU MDR / NOTIFIED BODYAssess for "significant change"per MDCG 2020-3 guidanceDocument OnlyEvaluate PathwayMay Need SubmissionSubmission Required

Change Assessment Tool

Select the type of design change you are evaluating:

Key Regulatory References

FDA - Design Changes

  • • 21 CFR 820.30(i) - Design Changes
  • • FDA Guidance: Deciding When to Submit a 510(k)
  • • FDA Guidance: The 510(k) Program

EU MDR - Changes

  • • MDCG 2020-3: Significant Changes Guidance
  • • EU MDR Article 120 (Transitional)
  • • Notified Body procedures

Important Disclaimer

This tool provides general guidance only. Actual notification requirements depend on your specific device, classification, certifications, and the complete risk analysis. Always consult with your regulatory affairs team, quality team, and certification bodies before implementing design changes. Requirements vary by certification body and regulatory authority.