Medical cable assemblies are often a hidden failure point in device design. Poor specification can lead to signal degradation, mechanical failure, sterilisation issues, and ultimately costly redesigns or field failures.
Whether used in diagnostic systems, surgical equipment, or monitoring devices, cable assemblies must be engineered to meet the precise electrical, mechanical, and environmental demands of the application.
At Novara Technologies, we support OEMs and innovators in developing reliable, manufacturable interconnect solutions for medical devices—combining engineering expertise with Design for Manufacture (DFM) from the outset.
Start with Clear Application Requirements
Every successful cable assembly begins with a detailed understanding of how the product will be used in the real world.
Key questions to define early include:
- Is the cable single-use or reusable?
- Will it undergo repeated flexing, torsion, or handling?
- Does it need to withstand cleaning agents or sterilisation processes?
- What are the electrical performance requirements (signal integrity, shielding, impedance)?
Failure to define these requirements upfront can result in premature wear, signal loss, or connector
failure during use.
Critical design considerations include:
- Flex life and bend radius
- Strain relief effectiveness
- Connector mating cycles
- Environmental exposure (fluids, temperature, chemicals)
- Biocompatibility (for patient-contact applications)
Material Selection: Performance, Compliance, and Longevity
Material choice is fundamental to ensuring reliability in clinical environments.
Typical considerations include:
Cable Jacket Materials
- Silicone – highly flexible, ideal for high-flex applications
- TPU / TPE – durable, abrasion-resistant, and easier to process
- PVC – cost-effective but limited for demanding medical environments
Sterilisation Compatibility
Materials must be matched to the intended sterilisation method:
- Ethylene Oxide (EtO)
- Gamma irradiation
- Autoclave (high temperature, high pressure)
Incorrect selection can lead to:
- Material degradation
- Cracking or embrittlement
- Reduced mechanical performance
Shielding & Conductors
- Braided shielding for flexibility and durability
- Foil shielding for high-frequency signal protection
- Conductor strand design affects both flexibility and electrical stability
For patient-contact components, materials may also need to meet ISO 10993 biocompatibility requirements.
Connector Design and Overmoulding
The connector interface is one of the highest-risk areas for failure.
Connector Considerations
- Secure and reliable mating
- Appropriate pin density and layout
- Ease of use for clinicians
- Cleanability and hygienic design
Overmoulding Benefits
Overmoulding is often essential for medical applications, providing:
- Improved strain relief to prevent conductor fatigue
- Enhanced sealing against fluids and contaminants
- Better ergonomics for repeated handling
- A more robust and clinically suitable finish
Poor strain relief design is a common cause of cable failure, particularly in high-flex applications.
Design for Manufacture: Avoiding Costly Redesigns
A robust design must also be manufacturable at scale.
By incorporating Design for Manufacture (DFM) principles early, it is possible to:
- Improve production consistency
- Reduce variability and defects
- Optimise cost without sacrificing performance
- Accelerate transition from prototype to production
At Novara Technologies, we work with customers from early concept through to production, refining designs to ensure they are both technically sound and commercially viable.
Common Mistakes in Medical Cable Specification
Even well-designed devices can fail due to avoidable cable issues. Common mistakes include:
- Underestimating strain relief requirements
- Selecting materials incompatible with sterilisation
- Ignoring cable routing and bend radius constraints
- Over-specifying components, increasing unnecessary cost
- Failing to consider long-term mechanical fatigue
Addressing these risks early can significantly improve product reliability and lifecycle performance.
Standards and Compliance
Medical cable assemblies often need to align with key industry standards, including:
- ISO 13485 – Quality management systems for medical devices
- ISO 10993 – Biological evaluation of medical materials
- IEC 60601 – Safety and performance of medical electrical equipment
Designing with these requirements in mind helps streamline regulatory approval and reduces risk during validation.
Partnering for Reliable Interconnect Solutions
Specifying a medical cable assembly requires a balance of engineering detail, material expertise, and manufacturing capability.
At Novara Technologies, we support:
- High signal-count and complex interconnect systems
- Custom cable and connector design
- Prototype development and validation
- Scalable manufacturing and supply
Our experience across medical and other high-reliability sectors allows us to deliver solutions that perform consistently in demanding environments.
Frequently Asked Questions
What is the best cable material for medical devices?
It depends on the application. Silicone is ideal for flexibility, while TPU offers durability. The correct choice depends on flex requirements, environment, and sterilisation.
Can medical cables withstand repeated sterilisation?
Yes, but only if materials are selected specifically for the sterilisation method (e.g. EtO, gamma, autoclave).
How do you design cables for high-flex applications?
By optimising conductor stranding, shielding type, jacket material, and strain relief design.
What causes most cable failures in medical devices?
Mechanical fatigue, poor strain relief, and material incompatibility with the operating environment.
Discuss Your Application
If you are developing a medical device and need a reliable, manufacturable cable assembly, Novara Technologies can support you from concept through to production.
Get in touch to discuss your project and requirements.