Selected earlier project
Miniature high-power flex coupler
This connector assembly was developed for an implantable-device prototype that needed six contacts, each capable of carrying two amps at 1,000 volts continuously, inside a welded titanium bellows only a quarter-inch in diameter.
Electrical isolation, overall length, wire fatigue, assembly variation, and supplier capability interacted tightly. A thin molded nylon cup simultaneously provided alignment, retention, dielectric separation, and strain relief. Custom multi-strand wire, controlled lengths, clean PCB fabrication, and careful inspection were required to survive flex testing without making the assembly too long.
The product passed customer testing and moved into a manufacturing line established in Costa Rica, although the customer’s larger device did not reach market. The project was a practical lesson in GD&T, supplier development, process design, and treating manufacturing constraints as part of the system rather than a downstream concern.
