Minnesota Wire; a Leader in Advanced Medical Robotics Technology

Minnesota Wire has been designing, testing, and manufacturing custom wire, cable, and cable assemblies for the medical industry since 1968. Custom medical products are our primary focus and largest market segment. We serve customers ranging from start-ups to industry leaders.

Whether it’s Engineering Services, Custom Overmolding, Medical Wire Extrusion, Custom Cable Assemblies, Rapid Prototyping, or Test and Validation, Minnesota Wire can assist.

Let’s Talk!

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Still Not Convinced?

Read one of our Case Studies, and learn more about Minnesota Wire’s capabilities and expertise.

Case Study

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

Our Capabilities

Completed Wire and Cable Assembly


We cut the wire to the desired length on a wire-cutting machine. The wires are then stripped to expose the metal. Next, the wires are fitted with terminals or connector housings. Finally, the cables are assembled and clamped together according to the design specifications.

Cable Coiling

We offer a wide variety of coiling constructions. Our coil cords are available in axial, tangent, and performed tails. Coil cords can be designed with controlled retraction force.


Our extrusion process creates a protective and aesthetic coating on a bare wire. The bare wire is pulled through the center of a die to create a colored, insulated jacket. This process is high volume and creates a continuous and consistent profile. Our fluoropolymer extrusion line allows for the insulation of wires and cables with aerospace qualified polymers. Please select Materials for a list of materials we extrude.

Fine Braiding

We braid round and flat shields. Our shields stop electromagnetic interference, block external noise, resist abrasion, increase overall pull and cut-through strength, and protect from fire.

Intelligent Cables

The integrated circuit and software on the circuit detect the charging requirements of the device into which the intelligent cable is plugged.


Insert molding enhances a cable assembly’s functionality, durability, and aesthetics. These enhancements are achieved by encasing areas of the cable assembly with plastics such as PVC, PP, TPEE, and TPR.

Overmolding allows for a strong bond between two different materials without the use of adhesives. We can overmold connectors, strain reliefs, grommets, yokes, and other applications.


We create functional prototypes. A working prototype gives you certainty in the design of your project. We can help you develop your custom design. We have years of experience designing for a myriad of applications. We can source the necessary materials to develop and manufacture your product. We can do it all in our facilities.

Robotic Termination

We can robotically terminate wires with the use of our MTX machine. This automated process offers significant cost savings for high-volume products that do not require custom terminations and overmolding.

Let’s Talk!

Fill out the form, and a member of our team will be in touch to assist.

  • Max. file size: 300 MB.
  • This field is for validation purposes and should be left unchanged.