Plug-and-play control design and interoperability of medical devices has now become a decisive mission of technological research. One of the reasons for these requirements is the ever increasing attention that the medical sector is paying these days to specific treatments each individual patient requires which mandates having medical devices that are customisable and, more importantly, are able to interact with each other to handle more complex tasks and, as well, avoid more risks. Currently, vendor-specific devices and proprietary communication systems have hindered clinical environments from thoroughly reaching these goals. Thus, this paper concentrates on the software development aspect of medical devices and proposes a novel approach for the development of distributed control logic for them using modular, reusable and interoperable software components based on the IEC 61499 function blocks (FB). This technology enables the control design of the entire application to be in one software tool and consequently, alleviates design complexity and development time. Following that, it presents a simplified case study to exhibit the viability of this methodology to be exploited for control software design of medical and rehabilitation devices.Keywords: medical robotics; plug-and-play software components; medical devices; distributed control design; IEC 61499; function blocks; upper-limb rehabilitation device; biomechatronics; biomedical robotics.Reference to this paper should be made as follows: Sorouri, M., Vyatkin, V., Xie, S. and Salcic, Z. (2013) Zoran Salcic is a Professor of Computer Systems Engineering at the University of Auckland. His main research interests include digital systems design, custom-computing machines, reconfigurable computing, processor and computer systems architectures, embedded systems and their implementation, design automation tools for embedded systems, hardware-software co-design, new computing architectures and models of computation and languages for heterogeneous systems and wireless sensor and actuator networks. He has published more than 250 peer-reviewed journal and conference papers, several books and numerous technical reports. He is a Fellow of the Royal Society New Zealand (Academy of Science) and recipient of Alexander von Humboldt Research Award. This paper is a revised and expanded version of a paper entitled 'Distributed control design of medical devices using plug-and-play IEC 61499 function blocks' presented at