Engineering Partnership From Concept to Volume

New Programs. Custom Connectors. Design Freeze. Scale-Up. Supply Resilience.

The best time to engage a cable and connector specialist is before the interconnect is designed in. That’s when our engineers can do the most to lower your risk — on performance, on approvals, on cost, and on supply. Our capabilities are what we make. This page is about where we fit in your program, from first requirements to volume production.

Where is your program today?

01Starting a new device program→ 02Nothing off-the-shelf fits→ 03Heading into design freeze→ 04Moving from prototype to production→ 05Building in supply resilience→
Situation 01

Bring Us In at the Start of a New Program

Too many OEMs treat the cable and connector as an afterthought — something to source once the device is designed. By then, connector choices, materials, and routing are locked in, and every compromise shows up later as cost, schedule slips, or reliability problems. Engage Gii early and our engineers help define the interconnect while it’s still easy to get right.

Sounds like you if…

  • You’re at concept or early development and the interconnect isn’t defined yet
  • Your team is strong on the device, less so on cable and connector design
  • You want manufacturability designed in, not fixed later
  • You need a partner who’ll still be there at volume production

How Gii helps

  • Requirements definition for the cable and connector
  • Custom connector design or build-to-print — whichever fits
  • DFM reviews before design freeze
  • US-based engineering and rapid prototyping
  • A single team from prototype through volume production
Start a New Program Case study: the reusable surgical device project →
Engineering and prototyping
Situation 02

Design a Connector When Nothing Off-the-Shelf Fits

Energy-based devices push interconnects hard — high voltage, tight profiles, sterilization, and single-use economics. When a branded catalog connector can’t meet your requirements or your cost target, Gii’s engineers design one that does.

Sounds like you if…

  • Catalog connectors force compromises on size, voltage, or mating
  • You’re building an RF, PFA, cryo, or electrosurgical system
  • You need single-use economics without sacrificing performance
  • You want a proprietary interface for your system

How Gii helps

  • Push-pull, locking, non-locking, and breakaway designs
  • 1–30+ contacts, high-voltage rated per IEC 60601
  • Biocompatible materials and custom overmolded housings
  • Single-use and reusable options
  • Fully proprietary architectures
Discuss Your Connector Read: RF ablation connector design considerations →
Purpose-built custom connector
Situation 03

Get to Design Freeze With Fewer Surprises

Late changes are where programs lose months. Gii reviews your interconnect for manufacturability, compliance, and documentation before design freeze — so verification, validation, and your regulatory file aren’t waiting on the cable.

Sounds like you if…

  • Design freeze is coming and the interconnect still has open questions
  • Your quality team needs traceability and documentation it can rely on
  • Your device must meet IEC 60601 electrical safety requirements
  • You’ve been burned by late-stage supplier changes before

How Gii helps

  • DFM and material review before freeze
  • Prototypes and first articles built, tested, and validated
  • Process capability studies and 100% electrical test
  • DHR/DHF documentation built to support your submissions
  • Change control that doesn’t slow production
Talk to Our Engineers Design guide: single-use medical connectors →
Validation and testing
Situation 04

Move From Prototype to Production Without Starting Over

The riskiest moment for a new device is the jump from prototypes to volume. With Gii, the team that engineered your interconnect is the team that builds it — with production at our nearshore facility in Heredia, Costa Rica or our manufacturing operations in Asia, matched to your volume and risk profile.

Sounds like you if…

  • Your prototypes work and volumes are coming
  • You don’t want to re-qualify a new supplier after design
  • You need a clear path from low volume to high volume
  • Your launch timeline can’t absorb a hand-off

How Gii helps

  • Production ramp at the right facility for your program
  • Qualification and first-article inspection
  • Nearshore in Heredia: same time zone, audit-accessible
  • High-volume manufacturing in Asia when scale demands it
  • Continuous improvement as volumes climb
Request a Quote Case study: ramping from 1,000 to 20,000 pieces a week →
Cable assembly production line
Situation 05

Build In Supply Chain Resilience From the Start

Geographic redundancy is easiest to design in before launch. Gii plans dual-sourcing and dual-region production into programs from the start, so a disruption in one place doesn’t stop your device — and your quality team gets a supply chain it can sign off on.

Sounds like you if…

  • A single supplier or single region would be a point of failure
  • Your quality team is asking for a dual-source plan
  • Long-lead components threaten your launch schedule
  • You want audit access to where your product is built

How Gii helps

  • Dual-region production across Costa Rica and Asia
  • Dual-sourcing strategies to eliminate single points of failure
  • Multi-country component sourcing and supplier qualification
  • Long-lead-time component management and buffer inventory
  • Supplier audits and ongoing performance monitoring
Discuss a Resilient Supply Plan See where we manufacture →
Nearshore manufacturing in Heredia, Costa Rica
How We Work

From First Quote to Full Production

Every Gii engagement follows the same structured path — from your initial inquiry through engineering, prototyping, and sustained volume production — designed to protect your schedule, your quality, and your margins at every step.

1

Inquiry &
Quote

A Gii engineer — not a sales queue — reviews your request and responds within one business day with clarifying questions and a program-specific quote path.

2

DFM & Value-Engineering
Review

Before anything is built, we review your design for hidden cost — over-specified materials, excess contacts, and expensive branded connectors that can be purpose-built for less.

3

Design &
Engineering

Our engineers finalize the cable and connector design — custom or build-to-print — with the regulatory requirements, documentation, and facility strategy for your program defined up front.

4

Prototyping &
Validation

Prototypes and first articles are built, tested, and validated — process capability, electrical test, and the DHR/DHF documentation your submissions depend on.

5

Production
Ramp

We launch production at the right facility across our Costa Rica and Asia manufacturing network — qualified, 100% electrically tested, and ramped to your volume targets.

6

Ongoing Management
& Cost-Down

We manage production, supply chain, and continuous cost improvement so your team stays focused on your device — not your supplier.

Why OEMs Choose Gii

The Difference Between a Vendor and a Partner

Global Reach, Single Accountability

Gii operates across the US, Costa Rica, and Asia — but your team has one point of contact. We manage the complexity of a global manufacturing network so you don't have to coordinate across multiple suppliers, time zones, and quality systems.

Built for the Regulatory Environment of Medical Devices

FDA-registered and ISO 13485 certified, our quality systems are designed around the documentation burden of medical device manufacturing — DHRs, DHFs, change control, and audit readiness built in from day one, not bolted on after the fact.

Supply Chain Resilience by Design

We build dual-sourcing and geographic diversification into every program from the start. When supply chain disruptions hit — and they do — our OEM partners are protected by a supply chain architecture that was designed for exactly that scenario.

Three Decades of Program Transfers

Manufacturing transfers are where programs go wrong. Gii has executed dozens of successful transfers — from OEM internal production, from other CMOs, and between our own facilities. That experience is what keeps your production running while a transfer is in progress.

$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 →

Don’t See Your Situation? Bring Us Your Program.

Every program is different. Tell us where you are — concept, design freeze, or scale-up — and a Gii engineer will tell you honestly where we can help.

Start the Conversation