The single biggest driver of cable and connector cost in medical devices isn't manufacturing overhead — it's the choice of connector itself. When OEMs default to expensive branded off-the-shelf connectors, they pay a significant price premium that compounds across every unit shipped. Gii's engineers design purpose-built custom connector solutions that meet your exact performance and regulatory requirements at a fraction of that cost. Paired with rigorous DFM reviews and material optimization on every program, that value-engineering approach is how Gii consistently delivers meaningful cost reductions for OEMs building energy-based devices — across electrophysiology, ablation, electrosurgical, orthopedics, urology, and pain management.
On the manufacturing side, Gii manufactures across its own nearshore facility in Heredia, Costa Rica and its established manufacturing operations in Asia, guided by US-based engineering — selecting the right facility for each element of your program based on capability, quality, and cost, rather than constraining you to a single location. That flexibility is a competitive advantage most contract manufacturers simply can't offer.
And while cables and connectors are always our deepest specialty, Gii's capabilities don't stop at the connector. For programs where it makes sense, we support full device-level builds — complete electromechanical assembly, PCBA integration, and finished device production — giving partners who want a single accountable team from concept through finished goods exactly that.
This is the core of what Gii does and where the greatest cost savings are found. Rather than specifying expensive branded connectors, our engineers design purpose-built alternatives — push-pull, locking, non-locking, and breakaway configurations — that match your clinical and regulatory requirements at a dramatically lower per-unit cost. Biocompatible, durable, and engineered from the ground up for your specific device.
Complete cable assembly from wire cutting and termination through final electrical test — 100% tested on every unit, no exceptions. We offer custom extruded wires, high-flex, shielded, coaxial, and multi-conductor cable options. Our DFM engineers review every design for opportunities to simplify construction, optimize materials, and reduce per-unit cost before production begins.
Cables and connectors are Gii's core — but our engineering and manufacturing infrastructure is built to go further. For OEM partners who need it, we support complete device-level production: full electromechanical assembly, multi-component subassembly, and finished medical device builds under ISO 13485. Whether you need a single sub-build handled or a complete turnkey program, Gii can be the single accountable partner from cable and connector sub-assembly through finished goods.
Surface-mount and through-hole PCB assembly for the electronics that live inside and around your cable and connector assemblies. IPC Class 2/3 standards with full component traceability, automated optical inspection (AOI), and X-ray inspection — precision electronics as part of a fully integrated cable and connector build.
Precision stamping and CNC machining of connector contacts, pins, shields, and housings to tight tolerances and high volume. Part of the custom connector design process — engineering the specific metal contact geometry your device needs rather than defaulting to a standard component that may be over-specified and overpriced.
Lubricity, biocompatible, and electrical performance coatings applied to cables and connectors with precision and validated consistency. Material and coating specifications are reviewed as part of our DFM process — ensuring you're using the right coating for your application, not an over-specified one that inflates your unit cost.
Dedicated ISO 8 clean room space with in-house sterilization — purpose-built for sterile and critical medical cable and connector assembly. Producing cables and connectors in a controlled environment within the same facility that does your molding and stamping eliminates costly transfer steps and keeps your sterile supply chain tight.
FDA-registered and ISO 13485 certified, with full IQ/OQ/PQ validation protocols and complete DHR/DHF documentation specific to cable and connector manufacturing. Our quality systems are built to support your regulatory submissions Our quality systems are built to support your regulatory submissions and ensure nothing ships unless it meets your exact specification.
See how these capabilities come together at each stage of your program:
That's what Gii's value engineering saved a $5 billion orthopedics OEM across 500,000 pieces — by re-engineering a six-component connector assembly down to two and consolidating three suppliers into one.
Read the case study →Share your requirements, sketches, or current design and a Gii engineer will review the interconnect with you — manufacturability, materials, and connector options — before decisions get locked in. No commitment required.
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