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Custom cables for medical devices

Sep 272012

Custom Cable

Custom wire and cable is often the choice for medical devices due to the complexity of the technology of new devices. Custom medical cables differ from applications in other industries because the medical cables are not only expected to perform but in many cases to withstand sterilization and be bio-compatible as well. When choosing the right medical cable it is always a great idea to contact a custom wire and cable manufacturer for material suggestions for your particular project.

Medical cables can be manufactured using a variety of materials depending on the use and requirements. Standard cables can be used in medical applications. Standard non medical cables are commonly used for internal wiring, equipment power cords and applications not requiring sterilization or patient contact. Custom cables are needed at times for these types of applications when a super flexible wire or cable is needed.

Many times medical cables need to meet special requirements for example, sterilization, flexibility or patient contact. Often Custom wire and cable is used for these devices. Product designers must tell wire and cable manufacturers what the sterilization process will be, the extent of patient contact and the overall use of the device and medical cable. Understanding the application will assist the custom cable manufacturer in choosing the right materials and construction for the medical cable.

Information to provide:

Disposable or reusable? Disposable cables do not require sterilization in most cases and can be made of less expensive materials such as PVC or PE. Reusable medical cables are many times subjected to sterilization and use materials that can withstand extended sterilization cycles.
Sterilization process. Choose an insulation or jacket material that can withstand repeated sterilization. Sterilization with chemicals, autoclave and E-beam are most common. Material choices can include silicone, TPE or Teflon®
Bio-compatibility. Let your custom cable manufacturer know if there are bio-compatibility requirements. Materials are available from implantable to minimal patient contact. Custom medical cable manufacturer can recommend the correct FDA grade materials for your application.
Flexibility requirements, abrasion resistance and special circumstances. Do you need an ultra flexible wire or cable? Does the cable need to be abrasion, high temperature, high flex or chemical resistant?

When contacting a custom cable manufacture be sure they are experienced in custom medical cables, have your list of requirements along with your design requirements such as number of conductors, cable diameter and the other basic data. A medical cable which will last and perform well depends on the information given during the design phase, provide your custom cable manufacturer with all the relevant information you have in order to get the right cable for your project.

If you would like more information on custom medical cables or would like to discuss your project, contact Calmont Wire & Cable to speak with an engineer.

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3 Reasons People Choose Custom Wire

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Sep 182012

Super Flexible Custom Wire

Wire is wire right? Why would anyone need custom wire? Wire is constructed differently, it is important to use a wire that was made for your type of application. There are many reasons people turn to custom wire. Custom wire can be manufactured to meet specific requirements such as, high voltage, extreme temperatures, high flex cycles and improved flexibility to name a few.

Three of the most common reasons people turn to custom hook up and lead wire are:

“My existing wire keeps breaking.” Wires that break and fail are usually not designed to be repeatedly flexed or bent. Conductor stranding is important in high flex environments. High flex custom wire is normally made with high strand count conductors and sometimes with alloys. Hook up and lead wires that are off the shelf are normally available in solid core, 7 or 19 strand. This wire is intended for static installations where the wire is not required to move once it is installed and is not intended for repetitive movement and high flex applications. As the fine strands break loss of conductivity and complete failure will occur. High strand count conductors will withstand this type of environment due to the construction and number of strands. High strand count wire can sometimes be purchased off the shelf, but in most cases need to be purchased from a custom wire and cable manufacturer. Custom lead wires can be manufactured with the application in mind using materials intended to withstand movement such as robotic /automation, handheld devices, and other applications.

“I need a more flexible wire for my project.” Ultra flexible wires are are manufactured using very high strand count conductors and flexible insulation and jacket materials which are hard to find ready made and off the shelf. Custom wire and cable manufactures specializing in super flexible wire and cable can assist you with your flexibility requirements. There are several types of insulation that can be used to make a wire extremely flexible. Silicone insulated wires are probably the most flexible wire available together with high strand count conductors the wire can be extremely limp even described as “noodle wire” even in the larger gauge sizes.

“I can’t find the wire I need anywhere.” This is usually the case when a small gauge wire is needed, retrofitting and repairs, or a wire becomes obsolete. Wire gauges smaller than 30AWG can be difficult to find off the shelf, turning to a custom wire manufacturer that works with small gauges is usually the only option. Custom wire can be made smaller than 50AWG by some custom wire manufacturers. Often we have requests for hookup wire and cables for equipment that needs to be repaired, updated, or overhauled. This type of situation the existing wire can’t be identified or the existing wire needs to have improved performance. Custom cable manufacturers can reverse engineer existing wire and suggest better construction or materials to achieve the improved performance and longevity of the wire.

Contact a custom wire and cable manufacturer to find out if a custom wire is needed for your application. Starting out with the right wire will save time and money in returns, repairs and redesign. They may tell you that a custom wire design is not needed and an off the shelf wire will work just fine for your application. If you have questions about which wire is right for your application, contact us today and we will be happy to assist you.

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Custom Ultra Flexible Hook Up Wire by Calmont

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Sep 132012

For over 50 years Calmont has been manufacturing custom wire and cable and we are known for manufacturing extremely flexible wire and cable. Calmont’s proprietary lines of ultra flexible hook up wires are a perfect fit for applications with demanding flex requirements. When you need ultra flexible wire from 40AWG to 4/0, we can help you.

Calmont’s product line up for ultra flexible hook up wire includes:

SuperFlex– SuperFlex was pioneered and developed by Calmont for the exacting commercial and military markets. Specially compounded and plasticized polyvinyl chloride insulation applied over ultra fine stranded wire yields a finished wire with a longer flex life and a higher flexure index level than that attainable with ordinary PVC insulated wire. It’s ideal for low temperature, high flex applications. SuperFlex is commonly used for disposable medical devices, robotics, sensors and assorted cost sensitive commercial applications. 26 and 29AWG is normally in stock.

FluoroFlex – Calmont’s precision extrusion techniques combine the superior properties of FEP with the durability of a highly stranded conductor to produce an unequalled product. It is small and lightweight, yet will withstand the severe and repeated flexing that usually destroys other fluorocarbon insulated wires. FluoroFlex is highly versatile and suitable for broad usage in aerospace, computer, and medical electronics. Being chemically inert, FluoroFlex can be used for medical implantation. It has the smallest finished diameter of any of the Calmont high flex products. FluoroFlex’s excellent dielectric properties also make it ideal for data and audio applications. 26 and 29 AWG is normally in stock.

SiliFlex – SiliFlex is distinguished by its extreme limpness and flexibility. It is the most limber of all the high flex products offered by Calmont. Silicone rubber insulation compounds are inherently soft and pliable and resist the plastic flow that characterizes many insulation systems. Silicone compounds can be tailored to meet a variety of demands such as extreme high and low temperature requirements, flame resistance, flexibility, radiation resistance, strength and purity. SilifFlex is used extensively for robotic, aerospace and medical applications. Our popular Siliflex 26 and 29 AWG is normally in stock. Select colors and sizes in 50ft spools available at McMaster-Carr (contact us for part numbers).

SiliFlex Ribbon Cable – SiliFlex Ribbon Cable is produced from high stand, round copper conductors that are individually insulated with silicone rubber. They are then laid parallel and bonded in an extremely flexible flat form. With this flat configuration, the mechanical load applied to the cable is distributed over the total width of the cable, allowing for improved heat dissipation and greater flex life performance over traditional round cables. SiliFlex Ribbon Cables are the perfect solution for applications like computer hardware hook up, aircraft, and industrial automations. Siliflex Ribbon Cable is high temperature resistant (150-200 Cº) and is tested to withstand several million flexes without breakage. SiliFlex Ribbon Cable is manufactured in accordance with, and can be certified to meet, the applicable requirements of MIL-W-16878, Type F. This product is made to order with a quick turnaround. You pick the number of conductors, AWG, conductor plating and colors.

Calmont also manufactures hook up wire in a variety of other materials for all types of applications including high voltage, robotics, medical, aerospace and others. Contact us today to get the right wire for your project we can assist you with your wire design and suggest the best design for your application.

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