Medical Industry Solutions

Problem: Mismatched colors; ultrasonic welding flash; difficult assembly; poor supplier delivery.
Solution: Redesigned part; added energy directors to eliminate flash; changed vendors; molded in graphics (replaced silk-screened).
Results: Reduced part cost with improved delivery and quality; improved throughput; eliminated flash removal rework and time.

Problem: Needed a method to connect IEC safety connectors to existing pacemaker programmer.
Solution: Inserted two female Hypertronics into a silicone overmolded unit cabled to a circular programmer connector.
Results: Solved the IEC safety problem permitting the continued use of all the existing programmers. Silicone molding provides a sterilizable assembly.

Problem: FDA requirement placed on all medical device manufactures for leads that meet IEC 601 spacing.
Solution: TSE tooled a shrouded pin and adapter to support customers. They are designed for various custom assemblies.
Results: Met customers' need for quick response to a government mandate at minimum cost.

Problem: Flex circuit 'floated' in the mold, reducing yield. RTV seal at cable entry was unsightly.
Solution: Created tooling to locate the circuit in the mold. Added tubing beneath the overmold to create the seal.
Results: Yield was increased by 20%, reducing inspection and labor, while improving aesthetics.

Problem: Multiple signal leads needed an intuitive, ergonomic interconnection solution.
Solution: TSE designed and molded a switchable attenuation network into a compact hand-held instrument combining all signal leads.
Results: Created a surgeon friendly, unique device that complements the customer's implant programmer.

Problem: With many part numbers and various cable assembly types, there were too many sources to manage.
Solution: TSE combined all cable types, sourcing some in our Minnesota plants and importing others from our Asian location.
Results: Customer saves money on the cable assembly cost and the cost of managing so many suppliers.