Custom Medical Cable Assemblies for Imaging, Monitoring, and Surgical Systems

Our wire preparation supports stranded or solid copper conductors from AWG 40 to 120mm², cut and stripped using precision rotary blade equipment with insulation length control that meets IPC standards.

Terminations include crimped, tinned, or soldered ends using thermal stripping or mechanical separation, depending on the jacket type.

Operator workflows are controlled by assembly drawings and part-level routing sheets, with crimp height and pull strength measured at every 50 units per lot.

Conductor length tolerances are maintained within IPC rating standards.

We support extrusion and jacketing using TPU (with wear resistance 3 to 5x greater than natural rubber), TPE, PVC, and silicone with OD ranges between 1.5 mm and 9.0 mm, verified before the production process and staged in ESD-safe cable trays.

Jacket ends are stripped with careful control to protect underlying shielding or fillers. OD concentricity, jacket roundness, and sheath continuity are inspected visually and dimensionally using calipers and ring gauges.

Cut jackets are fitted during termination to preserve jacket edge integrity and ensure mechanical retention at crimp or overmold interfaces.

Overmolds are formed using aluminum or steel molds matched to cable geometry, with cavity fills for right angle, inline or multicore split configurations.

WellPCB uses elastomeric compounds rated Shore A65 to A90 and cured at 302 to 356 °F (150 to 180 °C), providing thermal integrity throughout sterilization cycles.

Molded joints undergo tensile validation in high strength test configurations and are visually checked for air gaps, flash, or shrink distortion. We also support ferrule encapsulation, boot flaring, and strain relief formation directly over split cable exits.

Cable terminations include 2 to 64-position connectors across circular, coaxial, and rectangular interfaces, including formats used by LEMO and ODU, with contact pitch support down to 0.635 mm and insulation diameter match up to 1.8 mm per lead.

Pinout maps are matched against customer schematics using continuity probes or automated connector testers.

Contact depth is verified using cavity inspection tools, with overinsertion or back-out limits kept to the smallest offset from the spec centerline.

Signal pairs are twisted, aligned, and jacketed before routing to final positions for panel mount or inline mating.

Harness assemblies are constructed on fixtured panels with split lengths, connector types, and bend radii controlled to within the IPC Standard of the routing layout.

All breakouts are labeled using heat-shrink tubing or laser marked ID bands placed at defined offset intervals.

Branches are sleeved with expandable braid or PVC tubing, with inner bundles secured using crimp collars, cable ties, or internal potting compounds.

Cable support includes routing across support saddles, strain-loop gaps, and anchor points used for robotic, diagnostic, and surgical medical equipment.

Electrical testing includes continuity measurement across all conductors, insulation resistance up to 500 MΩ, and hi-pot withstand testing at up to 1500 VDC, depending on the assembly rating.

Signal cables are evaluated using TDR for impedance consistency, return loss, and propagation delay.

Test logs are tagged to batch numbers and cross-referenced to routing drawings. Failures are documented by pin number, error type and corrective action to isolate mechanical or operator faults.

These test outcomes are important in applications where cable failure could disrupt patient monitoring or life support functions.

Assembly is conducted in electrostatic protected zones using grounded workstations, wrist straps, and ESD-rated trays for cable staging.

Incoming wire, terminals, and connector shells are tested for conductivity and surface resistance in accordance with ESD S20.20 guidelines. Tools and fixtures are cleaned and revalidated daily for contact wear, static buildup, and alignment drift.

Connectors are mated only once during test and final inspection to reduce insertion wear and preserve contact plating integrity in high cycle builds.

We support prototype builds starting at 1 unit through volume production exceeding 2.5 million assemblies per year, with documentation tracked per batch, operator ID, material code, and connector lot.

Each build includes revision controlled drawing, inspection signoff, and post-test report stored by work order number. Assembly aids include custom crimp blocks, overmold tooling, bend fixtures, and connector jigs, all tailored to each part number.

Scaling to production includes staged fixture storage, mold duplication, and documented lot-to-lot consistency control.