Choose the custom or ready-made medical connector difference

There are many factors to consider when choosing a custom or off-the-shelf medical connector, and the benefits and disadvantages of both can surprise you.

One of the decisions companies face when designing new medical devices is to choose a connector and a matching outlet. For some applications, standard (or off-the-shelf) connectors are a viable option; for other applications, custom or hybrid connectors may be more appropriate.

Reasons to consider choosing a custom medical connector include:

• Requires a unique design to ensure that only certain cables or connectors can be plugged into the device
• The shape of the connector must match the shape of the medical device
• It is necessary to carry multiple signal types (high voltage, low voltage, high bandwidth, data, thermocouple) in a single connector.
• Better meet cost targets
• Need to customize the logo or mark
• Prevents the insertion of incompatible connectors with a unique pin-to-socket pattern or connector shape for improved security

Custom connectors typically include engineering and mold manufacturing costs, and these upfront costs can be an obstacle to choosing a custom connector solution. However, when the cost of the connector design and mold is determined, the cost of custom connectors is typically much lower than that of off-the-shelf connectors.

Physical characteristics
Custom connector solutions are available to meet the physical characteristics required. Custom connectors are designed, and the plug-in and splicing forces can be tailored to specific customer requirements. This plug-in and splicing force is achieved by each pin. It is constructed by friction with the socket and the mechanical interface of the connector and the socket.

Moisture protection is often a consideration in medical interconnect systems. Off-the-shelf connectors typically incorporate an outer casing and a pre-molded shield that typically does not provide the required level of ingress protecTIon when these components are assembled in a finished connector. However, custom molded connectors can be designed to have any desired IP rating.

In addition, the supply of connectors from major manufacturers can also be a problem, with lead times typically ranging from 8 to 16 weeks. When the mold is finished, the lead time for custom connectors may be much shorter than for off-the-shelf connectors.
Design requirements
Developing detailed design requirements is one of the first steps in determining whether a custom or standard connector is the best choice. Factors to consider include:

• Number and type of contacts (pins or sockets and specifications for each)
• Cable configuration (ECG, defib, power supply, analog, digital, bandwidth, pneumatic, fiber optic or a combination of two or more)
• Cable diameter, material and shape
• Regulations and environmental protection levels (RoHS, REACH, ISO 10993, UL)
• Strain relief requirements
• Connector and cable shielding requirements
• Voltage and current requirements
• size limitation and / or physical size required
• Intrusion Prevention (IP) requirements or ratings
• The number of required plug or splicing cycles
• Locking mechanism (if any)
• Keying requirements
• Required plugging and detaching force
• Cleaning, disinfection and sterilization requirements
• Logo, marking and serial arrangement

Custom connector components
Custom connectors typically include an injection molded rigid plastic insulator with pins or/and sockets inserted. The most common is to solder or crimp the conductor to the pin or socket. The assembly is then molded using a rigid material, such as polypropylene, to hold the structure together and provide physical strength. Secondary overmolding using materials such as thermoplastic resins or silicone resins provides the connector with the desired color, coating, appearance and feel.
Hybrid connector

For some applications, a hybrid connector may be the best choice. Hybrid connectors are off-the-shelf connectors with custom features such as overmolded handles or strain relief. Hybrid connectors may have lower design and tooling costs than custom connectors, but the finished product has the look, feel, and some additional performance benefits of a custom connector. In addition to lower engineering costs, hybrid connectors are designed and developed to be shorter than fully custom connector designs.

Custom or hybrid connectors provide unique features and benefits for medical devices, enabling each design element with less compromise than using off-the-shelf connectors for improved safety and reliability, while custom connectors It may be a more cost effective solution. However, custom and hybrid connectors typically require larger engineering and mold investments than off-the-shelf connectors.
Through the above analysis, I believe that readers have already understood the difference between choosing a custom or ready-made medical connector.

Konnra Electornics offers customized solutions for medical devices (including medical connectors and medical harnesses), and since it has signed an NDA with related customers, it has not been shown here. If you are interested, you can visit the OEM/ODM in the solution on our website and enter your requirements. Kangrui Electronics will contact you in the first time and provide you with a perfect solution.