Cable & Connector Capabilities

Engineering-Led Custom Connector Design & Cable Assembly for Energy-Based Medical Devices

Value Engineering — The Gii Difference

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.

Custom Connector Design & Molding

Custom Connector Design & Engineering

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.

  • Biocompatible material selection and validation
  • Push-pull, locking, and non-locking configurations
  • Backward compatible design engineering
  • Miniaturization and tight tolerance capabilities
  • Full DFM review and process validation
Cable Assembly Manufacturing

Cable Assembly Manufacturing

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.

  • Custom wire extrusion and formulation
  • High-flex, shielded, and coaxial options
  • Multi-conductor cable capabilities
  • Full traceability from raw material to shipment
Electromechanical Assembly

From Cable Assembly to Full Device Build

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.

  • Cable-to-device subassembly integration
  • Complete electromechanical device builds
  • Multi-component and multi-supplier coordination
  • In-process quality controls at every stage
  • Prototype through volume production
  • ISO 13485 quality management throughout
PCB Assembly (PCBA)

Connector Electronics & PCBA

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.

  • SMT and through-hole assembly
  • IPC Class 2/3 standards compliance
  • Full component traceability
  • AOI and X-ray inspection
  • Medical-grade quality assurance
Metal Stamping & Machining

Metal Stamping & Contact Fabrication

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.

  • Precision stamping and forming
  • CNC machining capabilities
  • Connector contacts and shields
  • Tight tolerances at volume scale
  • Material expertise and supply chain
Coating & Surface Treatment

Coating & Surface Treatment

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.

  • Lubricity coatings for device insertion
  • Biocompatible surface treatments
  • Electrical performance coatings
  • Single-use and reusable device support
  • Process validation and documentation
Clean Room Manufacturing

Clean Room Manufacturing

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.

  • ISO 8 clean room production
  • In-house sterilization chambers
  • Sterile device manufacturing support
  • Critical device production capabilities
  • Environmental monitoring and controls
Validation & Quality

Validation & Quality — Built for Zero-Failure

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.

  • IQ/OQ/PQ validation protocols
  • Full DHR/DHF documentation
  • FDA-registered QMS
  • ISO 13485 compliance
  • Supplier and process audits

That's What We Make. Here's Where We Fit.

$7M

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 →

Bring Us In Early on Your Next Program

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.

Start a Conversation With Our Engineers