Case Studies

Automated External Defibrillator (AED) Electrical Interconnects

The Challenge

An industry-leading manufacturer of automated external defibrillators needed an electrical interconnect between its power unit and the patient pads.

Zero-failure, 20 gauge wire

Custom terminations at the AED unit and the pads used to shock the patient

Rapid turnaround on design

The Solution

Minnesota Wire worked with the customer to produce an interconnect solution that exceeded all the OEM’s requirements, including turn-around time.

Guaranteed solution for high-voltage, life-critical pulses

Complete solution: termination to termination

Complete in-house design, engineering, prototyping, test and measurement, and manufacturing

Carbon-Fiber Twisted Pairs for EEG and fMRI

The Challenge

Capture Electroencephalography (EEG) Data Concurrently with Functional Magnetic Resonance Imaging (fMRI)

Kappametrics’ flagship product, f-EEG™, employs noise cancellation techniques to eliminate large radio frequency and electrostatic and magnetic noise produced by the fMRI scanner. This enables the real-time collection of physiologic EEG data during fMRI.

The customer needed carbon-fiber twisted pairs with robust micro-terminations.

The Solution

Minnesota Wire worked with Kappametrics to design and produce custom carbon-loaded material. We created extremely small wires of carbon-fiber twisted pairs for robust terminal connectivity of the electrodes. The design, for a revolutionary skullcap device, ensured:

Guaranteed radio-translucence

A robust interconnect assembly for long product life

Zero-failure signal integrity due to dynamic in-process, in-house testing

Disposable Adult-Length Lead Wires

The Challenge

An electrocardiogram (ECG) OEM needed an adult-length pre-wired electrode.

Stringent new Medicare requirements for coverage of infections created a market demand for disposable ECG lead wires

Design required a “low-profile” assembly for ease of application and maximum patient comfort

The Solution

Minnesota Wire drew on its decades-long expertise with neonatal ECG electrodes to produce a robust and inexpensive design.

Engineered for zero-failure, one-time use

New adult-application length

Low-profile design using a highly conductive plastic tab

Eliminated the possibility of cross infection from patient to patient

Unique sonic welding process

Radiotranslucent design

Trusted Advisors for Over 50 Years!

We will work with you to develop the perfect custom solution for your unique needs: from Medical Devices to Deep Space Applications.

Drug Delivery System: Pain Management

The Challenge

An industry-leading manufacturer of patient drug infusion pumps needed a custom-designed switch with challenging requirements.

Heavy patient usage

Patient comfort and reliability

Custom terminations on both ends of the interconnect assembly

The Solution

Minnesota Wire worked with the customer to produce an interconnect solution that exceeded all the OEM’s requirements—in record time.

Custom overmolded switch design that guarantees ergonomic, comfortable use for patients with pain

Complete solution: termination to termination with guaranteed signal integrity

High strength, highly-flexible coiled conductor

Complete in-house design, engineering, prototyping, test and measurement, and manufacturing

Reusable Hi-Voltage Connector for Electrosurgical Assemblies

The Challenge

A medical device company needed a more robust and reusable interconnect solution between its surgical generator and the device it powers.

High voltage, high frequency

Reusable, flexible, and autoclavable

Produce the complex tooling in-house for added affordability and future redesign

Custom designed, over-molded interconnect solutions

The Solution

Minnesota Wire worked with the customer to produce a custom solution that exceeded expectations.

Highly flexible overmolding

Autoclavable up to 200 cycles

Load-bearing Kevlar strength member

Withstands 4,500 – 5,000 KV hi-pot test

Hearing Aid Tubes and Audiometric Systems

The Challenge

An industry-leading manufacturer of hearing aid devices needed a complete redesign of integrated hearing aid tubes for its products.

Devise a standard line of individualized acoustic tubes that will fit every human ear

Flexibility, durability, transparency, and comfort are paramount

Two-ended interconnect challenge

The Solution

Minnesota Wire worked with the customer to produce an acoustic interconnect solution that exceeded all the OEM’s requirements.

Custom designed set of 16 standard configurations to fit left/right, S/M/L/XL, and deep/shallow ears

Developed a unique standardized manufacturing process for ultimate repeatability. Produced all custom jigs and fixtures in-house

Exceeded transparency requirements—nearly invisible design

Soft, flexible, and functional poly-urethane design for wearer comfort

Proprietary interconnects to earbud and battery adapter

Produced vendor-managed inventory system to guarantee stock

Significant savings in unit cost

Trusted Advisors for Over 50 Years!

We will work with you to develop the perfect custom solution for your unique needs: from Medical Devices to Deep Space Applications.

Small Gauge Conductors and Custom Terminations

The Challenge

A medical device company was experiencing routine breakage of its extremely small gauge (42 awg) conductors in a mapping device used for lung biopsies. Due to their small size and inherent weakness, the assemblies were breaking at the conductor/connector interface, even with minimal pulling or twisting. Previous vendors had been unable to engineer a solution that would ensure strength in a limited gauge assembly.

The Solution

Minnesota Wire engineers crafted a unique extrusion process using off-the-shelf connectors. A linear Kevlar strength member was run around the outside of the wire bundle, improving overall strength and longevity, and radically improving the termination point. The strength of the termination went from near zero to a 20 lb. pull strength with no loss of mechanical or electrical properties. This custom termination made significant advances in the customer’s ability to diagnose through a biopsy.

Defense Aircrew Cabling System

The Challenge

The Program Executive Office (PEO) of Air Warrior needed a radical redesign of its cables for the Air Warrior system’s in-flight kneeboard. Air Warrior is the Army’s newest-generation in-flight ensemble, using mission-configurable modules.

MIL-STD, Overmolded, Ruggedized, EMI Shielded, and Fire-Resistant Materials

The Solution

Minnesota Wire worked with the customer to redesign and deliver a custom overmolded cable in record time.

Significant weight savings

Custom overmolded strain relief design

Manufactured to MIL-STD

Reinforced with ruggedized and fire-resistant materials

Custom-tailored for space and system changes throughout the design process

Designed with airborne operators in mind

Shielded for a high-EMI environment

Intercommunications Cabling System

The Challenge

The U.S. Air Force needed a quick turnaround on a redesign for a cabling system on the presidential aircraft’s intercommunications system.

MIL-STD, EMI Shielded, Ruggedized, and Fire-Resistant Materials

The Solution

Minnesota Wire worked with the customer to redesign and deliver a fully custom overmolded cable.

Unique robust shielding properties for a high-EMI environment

Significant weight reduction

Custom overmolded strain relief design

Manufactured to MIL-STD

Reinforced with ruggedized and fire-resistant materials

Custom-tailored for space and system changes throughout the design process

Designed with airborne operators in mind

Trusted Advisors for Over 50 Years!

We will work with you to develop the perfect custom solution for your unique needs: from Medical Devices to Deep Space Applications.

Military Soldier Wearable Interconnects System

The Challenge

The Program Executive Office (PEO) of the Future Force Warrior needed the next-generation Soldier Vest System to have a more reliable and soldier-friendly electrical interconnects system. The program manager needed a supplier who could provide a Total Systems Solution.

Wearable Computers and Interconnects Systems

The Solution

Minnesota Wire leveraged its active Department of Defense R&D effort and mature program management expertise to provide a total interconnects solution for the Future Force Warrior program.

Significant weight reduction on the total vest system

Options to the customer included Minnesota Wire’s proprietary elastomeric (stretchy) wire solution (iSTRETCH®)

Enhanced EMI/RFI shielding solutions for the battlefield environment

Complete in-house testing and subject-matter experts for rapid prototyping and delivery

Military Vehicle Communications System Cable

The Challenge

The U.S. Military needed M-ATV combat vehicles in theater ASAP. Production was held up due to an urgent need for a redesign to a cable used in a critical communications system. The customer wanted a response in three weeks.

MIL-STD, Custom Overmolded Strain Relief, Ruggedized, EMI Shielded, and Fire-Resistant Materials.

The Solution

Minnesota Wire worked with the customer to redesign and deliver a custom overmolded cabling system.

Custom overmolded strain relief design

Manufactured to MIL-STD

Reinforced with ruggedized and fire-resistant materials

Custom-tailored for space and system changes throughout design process

Designed with operators in mind

Replaced three cables with one ergonomic, integrated cable set

Significant space savings for vital panel mount on the communications backplane

Open-architecture design

Radically improved EMI-shielded design without adding excess weight

Robust EMI testing provided with in-house EMC Chamber and Signal Integrity Lab

Battlefield-ready for the most challenging EMI “noise” environments

Ruggedized Industrial Coil Cords

The Challenge

Build a Custom Ruggedized Coil Cord for a Demanding Outdoor Construction Machinery Manufacturer

The coil cord, part of a scissor-lift, needed to withstand tough environmental conditions. The coil cord was subject to heavy usage in an industrial environment. It needed to perform in conditions that ranged from extreme heat to extreme cold.

The cord had to retract easily after being fully extended over several days while exposed to the elements.

The Solution

Minnesota Wire worked with the customer to redesign a fully custom coil cord and radically improve its overall performance.

Full attention to customer needs and design inputs

State-of-the-art CAD design

Custom in-house tooling

Unique coiling processes and materials

Trusted Advisors for Over 50 Years!

We will work with you to develop the perfect custom solution for your unique needs: from Medical Devices to Deep Space Applications.

Temperature Probe Assemblies

The Challenge

Replace Silicone in a High-End Patient Monitoring Probe Assembly

A major medical OEM was looking for a supplier who could help reduce the unit cost for probe assemblies used in temperature monitoring. The OEM wanted to lengthen the product’s life as well as replace the proven silicon design that was used for years.

The Solution

Minnesota Wire worked with the customer to redesign a customized temperature probe assembly while meeting challenging cost and product life requirements.

Thermo-plastic replaced silicone for cost and longevity

Exceptional quality: advanced materials autoclavable 100 times at 134 degrees Centigrade—well beyond the U.S. temperature standard

Vertical integration: design, tooling, molding, extrusion, assembly, testing—all in-house

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