Helen Frankenthaler PCB Circuit Board R&D Center

medical electronics pcb assembly design

Medical Assemblies

ADVANCED MANUFACTURING EXPERTISE

Comprehensive Assembly & Manufacturing Capabilities

Medical device manufacturers need precision, compliance, and scalability in their custom cable assemblies. PCA-HPMS provides comprehensive vertically integrated solutions with fine wire processing, PCB assembly, medical cable and component integration, whole device manufacturing, and extensive testing within ISO 13485:2016-certified facilities.

Stripping & Wire Preparation
  • Fine-gauge wire processing (36-50 AWG), including ribbonizing and precision stripping.
  • Fine-pitch configurations designed to support miniaturized medical devices and components.
  • Soldering and assembly services tailored for high-density terminations.
PCB & Component Assembly
  • Direct connector assembly&wire-to-board bonding for secure integration.
  • Fine-pitch terminations down to .1mm and less for development projects.
  • Custom overmolding with medical–grade materials (PVC, TPE).
Full Assembly & Device Integration
  • Turnkey assembly solutions are available, ranging from simple subassemblies to fully packaged probes and devices.
  • Partial pigtailed cable assemblies can be provided for final OEM termination.
  • Sterilization testing is available upon request to support regulatory and performance requirements.
Test & Validation Expertise
  • Product validation includes: mechanical, electrical, and environmental testing to ensure comprehensive performance.
  • Scalable high-volume production is supported with in-line quality control throughout manufacturing.
  • Advanced wire processing and high-precision assembly are backed by rigorous quality control.

Ultrasound Probe Cable Assemblies

PCA-HPMS micro-coaxial cables minimize capacitance and signal loss, which supports high-quality images in ultrasound devices. They are ideal for ultrasound probes that demand high signal clarity, flexibility, and durability for reliable imaging and diagnostics.

Features & Benefits

  • Micro-coaxial bundles support strong signal transmission and long-lasting durability.
  • Low capacitance design enables precise, high-resolution imaging.
  • Flexible shielding and insulation options for customizable performance.
  • Compatible with standard and custom probe designs, including high-frequency transducers.

CMOS Camera Sensor Assemblies for Medical Endoscopes

PCA-HPMS CMOS camera sensor cable assemblies are built for medical endoscope applications requiring miniaturization and superior high-resolution image quality. With advanced expertise in ultra-fine wire termination and precision assembly, we ensure seamless integration with the smallest CMOS camera modules, delivering excellent video quality for catheters, endoscopes, and single-use medical devices.

Features & Benefits

  • Direct vertical soldering to the end face of the small sensor, ensuring secure, high-density connections in ultra-compact designs.
  • Fine-pitch termination for secure, high-density sensor connections.
  • Optimized for camera modules and sensors like OmniVision’s OVM6946 (1.1mm x 1.1mm) and OVM6948-OCHTA (0.65mm x 0.65mm).
  • Cable diameters range from 0.5 mm to 1 mm.
  • Cable design customizable to your unique specifications, including cable length, dimensional restrictions, and the need for LEDs.
  • Flexible and reliable designs suitable for minimally invasive procedures.
  • Medical OEMs can fully leverage the tiniest CMOS camera modules for next-generation imaging solutions thanks to PCA-HPMS precision soldering and integration expertise.

Catheter Fine Pitch Termination

Fine-pitch wire termination is vital in sensors, imaging systems, and diagnostic catheter applications. PCA-HPMS delivers custom micro-coaxial cables, twisted pair cables, and termination.

Features & Benefits

  • For miniature catheter applications, precision fine-wire terminations utilizing ultra-fine wire, including sizes down to 48 AWG.
  • PCA-HPMS offers micro-coaxial, twisted pair, and complex cable options for high-density, flexible designs.
  • Our proprietary high-strength copper alloy conductors provide superior mechanical strength and flexibility while supporting reliable signal integrity for diagnostic and therapeutic catheters.
  • Custom configurations are available to align with exact OEM specifications.

Nondestructive Testing (NDT) Cables

PCA-HPMS supplies cables and cable assemblies used in Nondestructive Testing (NDT) across a broad range of industrial applications. NDT methods, such as ultrasonic testing, detect cracks, holes, or other structural inconsistencies to ensure product quality and safety.

Features & Benefits

  • PCA-HPMS interconnect assemblies assist in transmitting data from sensors to detectors for accurate NDT evaluations.
  • Reliable NDT cables, assemblies, and components are engineered for harsh environments, ensuring consistent performance and system integrity.