Mechanical Cable Assemblies
Design expertise coupled with problem-solving skills, customer
interaction, and state-of-the-art equipment lead to robust and reliable
At NEI Systems our specialty is the manufacture of highly flexible,
custom cable assemblies with multi-conductor, composite cables ranging
from 12 AWG to 38 AWG. Coaxial leads may be incorporated into the
custom cable designs.
We commonly use connectors manufactured by companies such as Tyco/AMP,
Molex, Packard, FCI, JST, Hirose, and ITT Cannon, Lemo, and Fischer.
Contact us to discuss your design needs.
Endoscope video cable assembly
Doctors who diagnose and treat medical conditions through an endoscope
— a tiny, flexible tube-and-camera assembly that captures
images of internal organs — need the sharpest images possible.
That’s why a producer of endoscopy equipment came to NEI Systems.
Working with the company’s engineers, we custom-designed this
surgical camera cable assembly that delivers superior images. Thanks
to teamwork and sophisticated soldering techniques, the product
surpasses the client’s expectations.
information about the Endoscope video cable assembly
This endoscope cable assembly features:
- Low-noise, fine-wire video cable composed of 23 micro-coaxes
and discrete conductors, Teflon insulated, 34-36 AWG
- Custom-molded boots, machined soaker caps and cable nuts
- Failure-protected flex-circuit assemblies
- Epoxy-potted solder joints
aided inertial, backpack data cable
Land survey, aided inertial, backpack
Whether driven by whims of fancy or necessity, NEI Systems creates
interconnect solutions that will survive in whatever environment
they encounter. Affectionately known as the “octopus,”
the mechanical cable assembly pictured is one of a series of interconnects
used for power and data exchange on portable GPS surveying units.
The GPS backpacks require cable assemblies rugged and durable enough
to withstand extreme conditions, from desert sandstorms to arctic
blizzards. When this customer approached us, it was experiencing
field failures with its existing cable assemblies. With the help
of NEI Systems’ engineering staff, the cable assemblies went
through a complete redesign. The result is the “octopus,”
a mechanical cable assembly that is less bulky, more flexible, aesthetically
pleasing, highly reliable, and less expensive than the product it
Orthopedic drill cable
with circular push-pull connector
|Orthopedic drill cable
with circular push-pull connector
Pictured are examples of circular quick-release, push-pull connectors
used on some of New England Interconnect Systems’ mechanical
cable assemblies. When multiple sterilizations are required, cable
sheathed with highly flexible silicone in combination with this style
of connector is often the design of choice. NEI Systems constructs
cable assemblies combining the highest-quality cable with connectors
from the world’s leading connector manufacturers including LEMO™,
W.W. Fischer™, and ODU™. We also build cables that are
designed and priced for disposable, single-use applications.
Whether your company serves the medical equipment, automotive, telecommunication,
or industrial market, and when you require a durable, mechanical,
or molded cable assembly, NEI Systems is here to help.
pedal, silicone lay-flat cable
Medical foot pedal, silicone lay-flat cable
NEI Systems integrates the right materials for the job. Pictured
is a straight cable assembly produced for a medical foot pedal.
This assembly features a mechanical, circular connector soldered
to a silicone rubber-jacketed cable. Our supple silicone rubber-jacketed
cable assembly lies flat on the floor, making it ideal for examination
and operating environments. NEI Systems works with its customers
to satisfy all specifications, such as UL, CSA, ETO, and autoclave
Details: 10 conductor 24 AWG (105/44) tinned copper; FEP insulation;
overall braided copper shield; black silicone rubber jacket; circular
information about the Orthopedic Drill and Medical Foot Pedal
RF Generator Medical Cable Assembly 01
|Medical cable assemblies for RF generator
It doesn’t take long for our customers to understand this: New
England Interconnect Systems knows coiled cords and custom cable assemblies.
It also doesn’t take long for our customers to realize that
Neisystems works hard to establish strong working relationships.
These medical cable assemblies connect pain management and tissue
ablation probes to radio frequency (RF) generators. A manufacturer
of medical devices, our customer was producing the medical cables
in-house using New England Wire Technologies’ flexible silicone-jacketed cordage. However,
its production line support requirements were draining its engineering
and R&D resources. The client tried outsourcing before with unsatisfactory
results. What it wanted and needed was a global supplier that could
facilitate a seamless transition, produce continual quality and cost
improvements, and shorten its supply chain. To meet these needs, we
had one-on-one engineering meetings that opened up direct communication
lines and mutual site visits. After a time, this customer was convinced
we could support its immediate requirements, and, in conjunction with
R&D, design in low-cost solutions on new products.
Your company has unique issues and concerns that require unique answers
and solutions. Let us help.
RF Generator Medical
Cable Assembly 02
Flow meter, coax cable
assembly, silicone jacketed with BNC
Flow meter, coax cable assembly, silicone
jacketed with BNC
New England Interconnect Systems produces coaxial cable assemblies.
Bay Associates Wire Technologies/NEI Systems is equipped to produce a wide range of interconnect
products. The vast majority of these are custom designs for original
equipment manufacturers (OEMs). Coaxial assemblies, like the BNC
pictured here, may be single lead cable, or the coaxial lead may
be incorporated into a multi-conductor composite cable.
Our customers’ customers demand performance. So, we frequently
receive requests for cable assemblies that will hold up under extreme
conditions, such as coiled cords that will remain flexible at low
temperatures, or cable assemblies that can withstand pulling and
tugging without electrical failures or intermittence. For example,
the assemblies might attach to data input equipment used in warehouses.
With people jumping on and off forklifts, it is a fact of life that
cables will occasionally snag on the equipment and stress the connection.
We welcome products that have demanding performance specifications.
We thrive on the design challenge. To meet these challenges, we
rely on our team’s broad manufacturing experience and the
expertise of our suppliers.
Once in production, you can count on Bay Associates Wire Technologies/NEI Systems
to deliver quality parts, on-time.
is a registered trademark of LEMO-USA. W.W. Fischer™ is a
registered trademark of W.W. Fischer SA. ODU™ is a registered
trademark of ODU-USA. There is no association, cooperation, or sponsorship
between New England Interconnect Systems and ODU-USA or LEMO-USA
or W.W. Fischer SA.