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A medical device manufacturer required a customized cable assembly for an electrosurgical instrument operating under repeated bending and movement.
The project required a cable structure that could maintain mechanical durability, stable electrical performance, compact routing and reliable termination during repeated use.
The cable needed to balance flexibility and mechanical durability within a compact instrument structure. Simply increasing conductor size could improve mechanical strength while increasing cable size and reducing flexibility.
The engineering focus was therefore placed on conductor construction, insulation selection, cable diameter, bending performance and strain relief.
HOTTEN re-engineered the cable structure using customized conductor construction and fluoropolymer insulation.
The cable assembly was optimized for the required bending radius and mechanical routing conditions, with customized termination and strain-relief design according to the application requirements.
The prototype assemblies were evaluated through application-specific electrical and mechanical validation. For applicable medical cable designs, HOTTEN supports dynamic flex testing, including 300K+ flex-cycle validation according to defined test conditions.
The optimized cable structure provided an improved balance between flexibility, mechanical durability, compact construction and electrical stability for the target application.
The project demonstrates HOTTEN's capability to develop customized cable assemblies for electrosurgical and RF ablation equipment based on customer drawings, samples and application-specific engineering requirements.
| Engineering Factor | Project Consideration |
|---|---|
| Flexibility | Repeated bending and dynamic movement |
| Mechanical Durability | Conductor fatigue and cable structure |
| Cable Diameter | Compact instrument routing |
| Insulation | Fluoropolymer insulation options |
| Electrical Performance | Stable electrical characteristics |
| Termination | Customized connector and assembly requirements |
| Validation | Application-specific mechanical and electrical testing |
| Manufacturing | Prototype development to volume production |
HOTTEN supports customized medical cable assemblies based on customer drawings, samples, BOMs, connector specifications, pinout, cable length and application requirements.
Prototype → Engineering Validation → Reliability Testing → Production
