An optical microscope medical innovator was looking for a hybrid cable system that combined several cable elements such as fiber optics, USB data connection, and instrument signaling. The product had strict dimensional restrictions, and the fiber needed to endure being crushed by a 200 lb trolley. They also required the outer jacket to be medically compliant while maintaining a very high level of flexibility for its handheld use.
Over a period of months, our engineering team collaborated closely with the customer. Our team looked into various solutions to safeguard the fiber optics from crushing. However, many tubes that proved to be crush-resistant were either too rigid to maintain cable flexibility or would bend when crushed and not recover, creating a weak point for future fiber failures.
The next hurdle was creating a USB component that would transport data over their 10m application while preserving great flexibility. Last but not least, the jacket's material needed to be flexible and medically acceptable while also providing appropriate protection from tears when crushed by a hard, heavy wheel of the instrument cart.
Custom Full Turn-key Solution
Following the completion of the cable design, the customer requested the creation of a custom over-mold for their product, which would permit the cable to flex unhindered but still provide the necessary strain relief, all while interlocking with their equipment.
The BizLink solution enables our customers to combine all their connection requirements into a single circular cable assembly and is a more compact, full turn-key cable solution. The essential micro-tuning of the fiber is made simple by placing it inside a plastic tube. Only a unique custom cable solution developed by our experienced design specialists can produce an all-inclusive cable package while preserving high flexibility, flex life, and excellent cut/tear resistance.
Optimize Your Cable Design Project
When developing a new project, we highly recommend that you review the cable and assembly simultaneously. Our engineering team will review the overall design and suggest the best solution. Contact the team today to learn how BizLink can help you on your next project!