Molded Cable Assemblies
Increased flex life, pull strength, and custom connectors
are just a few of the benefits of plastic injection, overmolded
assemblies. These assemblies can be customized with company
logos and finger detents. At NEI Systems, we focus on our
customers unique applications and requirements. Through
the cooperative, brainstorming efforts of your and our design
teams, NEI Systems assemblies are fashioned to perform.
Our flex reliefs arc smoothly and our strain reliefs withstand
agreed-upon load requirements.
Molding materials include silicone, PVC, polyurethane, TPE, and polyester.
Stereo lithography modeling is available.
Contact us for assistance in designing a custom molded cable or cable assembly.
oximeter medical assembly
Pulse oximeter medical assembly
A leading manufacturer in the pulse oximeter market had a
problem. It needed an overmolded plug, complete with subminiature
sensors, for its newest pulse oximeter, a noninvasive device
that measures the amount of oxygen in the blood. But it’s
hard to find partners who can handle such intricate, exacting
work. NEIS’s reputation for top-notch engineering capabilities
and its state-of-the-art Mexican plant were the solution.
We have an ongoing collaborative relationship with this manufacturer
and continue to improve its product.
information about the Pulse Oximeter
This medical cable assembly features:
- Custom 9-pin D-subminiature
- Overmolded strain relief with custom latching mechanism
- High-flex cable with seven individual 28-gauge conductors
- Each conductor is composed of 40 strands of 44-gauge
- Two shielded conductors that isolate the signal and eliminate
- Shield constructed of 40 AWG tinned copper
- Polypropylene insulation
- Polyurethane jacket
equipment coiled cord
Clinical chemistry equipment coiled
Engineers developing a new clinical blood analyzer were on
the hunt for a competitive turnkey solution for their complex
cable challenges. They needed a coiled cord with connectors,
a photo sensor, and an intricate compound curve strain relief
with overmolded printed circuit board. They knew not just
anyone could develop this cord—they needed a partner
they could depend upon for high-quality components and assembly.
After auditing NEIS’s Mexico plant, the engineers knew
they’d found their supplier.
Working with their team, NEI Systems engineers analyzed the
cable design, spotted potential manufacturing problems, and
offered viable design options. We solved the issue of retractile
cord wear on the blood analyzer’s rotating shaft by
anchoring the cord with a small “Christmas tree”
off the shaft axis. The resulting cord allows for rotation
without abrasion while meeting additional exacting specifications.
This medical hematology instrument cable features:
- Molded, compound curve strain relief
- Photo-interrupter sensor
- Printed circuit board, .062" double sided
- 4 conductor 30 Awg (25/44) high-flex NEWALOY 61 shielded
- MTE connector with formed strain relief
cable OD .058 inches (1.4mm
|Fine-wire, molded mini-DIN assembly|
NEI Systems specializes in miniature fine-wire assemblies and
molded assemblies. This assembly looks simple enough, but the
cable consists of four conductors of 36 AWG (7/44) stranded
copper wire with an overmolded mini-DIN connector and flex relief.
Soldering miniature cable to mini-DIN connectors requires a
great deal of skill and know-how. To fabricate a plastic injection
overmolded part without damaging the solder joints demands exacting
pump cable, right-angle overmolded flex relief
Right-angle circular connector with
custom overmolded flex relief
This custom-designed, right-angle overmolded cable assembly
attaches to a portable auxiliary heart pump. Frequent communication
between NEI Systems’ and the customer’s engineers
led to a proprietary molded cable assembly that incorporates
off-the-shelf components with NEI Systems’ custom-molded
alternating rib, flex relief. Since this was a new product
and actual demand in the marketplace was unknown, NEI Systems
designed the tooling to meet the customer’s initial
low-volume requirement and cost target. As demand for the
product grew, the mold was scalable, and additional flex-relief
cavities were added to the tool to increase production
Our team of professionals will collaborate with you to build
highly reliable interconnect products.