Connectors Q&A
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With the trend towards smaller, portable devices, what are some of the key factors to keep in mind when choosing a connector for use in a medical device?Answered August 31st, 2009 by Expert:Improvements in portability and patient comfort cannot translate into trade-offs in accuracy and reliability. Accuracy and reliability often need to surpass that of the larger devices they replace. Because of space and weight constraints in these devices, embedded components need to be smaller and weigh less. A more efficient use of the system footprint can be realised with a smaller form factor contact/connector system that allows more space for critical functions.
Components are scaled-down or “miniaturised” but still need to perform with the best quality and highest reliability. New challenges in manufacturing arise with this trend. The connectors used in medical devices need to be more dense and more compact, and be made from materials that are best suited for smaller spaces.
Manufacturing hurdles result from:
- The connector’s mechanical geometry–moulding, machining and handling small parts with small features
- The electrical requirements–smaller distances between electrically charged parts can create challenges in voltage transmission and have an impact on the connector’s current carrying capability, driving the potential for compromises in accuracy and reliability.
These manufacturing challenges can be overcome by considering new materials, more extensive testing, and more accurate moulding and machining processes. Connectors featuring smaller components with 0.3-mm contacts, for example, meet the density, size and weight requirements of new medical devices coming on the market.



Global Industry Director at Hypertronics Corp. since October 2006, Anthony Kalaijakis is responsible for Hypertronics’ global business development for the medical market. With more than 20 years’ experience in the interconnect industry, Kalaijakis has led numerous new medical interconnect product designs, some of which are patented, and he has been instrumental in the development of the new ImplanTac implantable connectors, ClearImage nonmagnetic interconnects and a line of medical-grade miniature connectors.