High-Precision Terminal for Medical Electrosurgical Systems
In medical devices, especially electrosurgical equipment, electrical connections must meet extremely high standards for precision, stability, and safety. Even minor inconsistencies can affect signal transmission and device performance. A leading medical device manufacturer approached Qianwei Precision to develop a high-precision terminal solution for small-gauge wiring, capable of delivering stable crimping performance, low contact resistance, and reliable operation under medical-grade conditions.
Customer Requirements
Our customer, a medical device manufacturer, required a highly reliable terminal solution for electrosurgical equipment wiring harnesses.
Key requirements included:
- High precision crimping for small-gauge wires (AWG 24–26)
- Stable electrical performance with low contact resistance
- No defects such as burrs, cracks, or deformation
- Compatibility with medical sterilization environments
- Compliance with RoHS environmental standards
- Consistent quality for mass production
Qianwei Precision Solution
Qianwei Precision developed a custom banana-type terminal tailored for medical applications.
Our solution focused on:
- Precision stamping using tight tolerance control (±0.02 mm)
- Optimized crimping structure for small wire applications
- Nickel-plated surface for enhanced corrosion resistance
- Strict process control to eliminate burrs and structural defects
This ensured the product meets both mechanical reliability and medical-grade performance standards.
Performance Advantages
Excellent Crimping Reliability
Strong wire retention, no deformation during crimping, stable electrical conductivity
High Precision & Dimensional Stability
Manufactured with strict tolerances to ensure: Accurate fit with connectors Consistent performance in automated assembly
Medical-Grade Reliability
Designed specifically for: Sensitive medical equipment Low-current precision circuits High-reliability applications
Materials & Manufacturing
Parameter & Specification
- Material: High-quality Brass
- Thickness: 0.3 ± 0.02 mm
- Surface Treatment: Nickel Plating
Manufacturing Capabilities:
- Precision stamping technology
- Automated production lines
- Strict process control for defect prevention
Each terminal is produced with a focus on:
- Smooth edges (no burrs)
- Structural integrity
- Uniform plating thickness
| Wire Range | AWG #24 – #26 |
| Material | Brass |
| Thickness | 0.3 ± 0.02 mm |
| Surface Treatment | Nickel Plating |
| Working Temperature | -20°C to +85°C |
| Electrical Rating | Low current / low voltage |
| Product Type | Banana-Type Terminal |
Testing & Certification
To ensure product reliability, Qianwei Precision implemented comprehensive testing:
Quality Inspections:
- Dimensional accuracy verification
- Surface quality inspection
- Burr and crack detection
- Deformation inspection
Performance Testing:
- Crimping strength test
- Contact resistance test
- Oxidation resistance evaluation
Certification:
- RoHS compliant
All products passed:
- 100% visual inspection
- Functional and structural validation
- Environmental compliance requirements
Results & Customer Feedback
After implementation in mass production, the customer achieved:
- Stable and reliable electrical connections
- Improved assembly efficiency
- Zero defect issues during production
- Consistent product performance
Customer Feedback:
- “Excellent dimensional accuracy”
- “Smooth crimping process”
- “Reliable performance in medical applications”
Why Choose Qianwei Precision?
Qianwei Precision is a trusted manufacturer of high-performance electrical terminals for demanding industries.
Our Advantages:
- 1800+ production molds for fast customization
- Advanced precision stamping technology
- Strong experience in medical and high-reliability applications
- Strict quality control systems
- Support for OEM/ODM projects
We specialize in:
Products
FAQ
Qianwei Precision provides precision terminals and connectors suitable for medical devices such as patient monitoring systems, diagnostic equipment, imaging devices, infusion systems, and laboratory instruments, supporting both signal and low-voltage power transmission.
Yes. Our manufacturing processes follow strict quality management systems, and our products can be supplied in compliance with relevant standards such as ISO 13485 and RoHS. Medical-grade material selection and process controls are available upon request.
Our connectors are engineered with precise contact geometry, stable contact resistance, and controlled materials to minimize signal loss, electrical noise, and intermittent connections—critical for accurate data transmission in medical devices.
Absolutely. We offer custom design and manufacturing services, including terminal structure optimization, material selection, plating options, and dimensional tolerances to meet specific medical device design and regulatory requirements.
Our connectors can be manufactured using materials and surface treatments that provide resistance to moisture, cleaning agents, and mild disinfectants commonly used in medical facilities.
We provide technical consultation, rapid prototyping, engineering support, and stable long-term supply to help medical technology companies reduce development risk and ensure consistent product quality.
Contact
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