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Cables may not be the first thing that comes to mind when talking about medical catheters. However, these tiny harnesses play a crucial role behind the scenes, transmitting power, data, or sensor signals where doctors need them most. In this case, “good enough” is not good enough. These cables must be biocompatible, meaning that they do not irritate or react when in contact with the human body.
At Romtronic, we have seen firsthand the importance of cable harnesses to modern conduit design. Our job? Ensuring that cables not only function but also work safely, consistently, and reliably, even under stress (both literally and metaphorically). Let’s take a closer look at the importance of biocompatibility, the uniqueness of cable harnesses, and how Romtronic helps medical device manufacturers stay ahead of the curve.
Why Biocompatibility Matters
In medical devices, biocompatibility refers to the ability of the materials used to prevent allergic or toxic reactions in the body. It can be interpreted in this way: If a cable is to enter or come close to a patient’s body – even if it only touches the skin – it must be biocompatible, meaning it should not cause any unusual rashes, leakage of chemicals, or long-term health risks.
That’s where standards like ISO 10993 come in. These standards enable manufacturers to determine which materials are safe for skin contact, internal use, or both, thereby ensuring the safety of their products. The materials we’re discussing include insulation, jacketing, and the tiny connectors at the end of wires.
What Makes Medical Catheter Cable Harnesses Unique
Medical catheter cables are not your everyday electronics wiring. They’re smaller, more flexible, and held to higher standards. Here’s what sets them apart:
1. Biocompatible Materials
Not only do we need to choose durable materials, but we also need to choose materials that have been rigorously tested for safety. Silicone, PTFE (an ultra-smooth plastic) and gold-plated contacts are all common choices. Why gold? It won’t corrode and has excellent conductivity. The key is that each material must be verified for safety when used on or in the human body.
2. Flexibility & Miniaturisation
Conduits are getting thinner and more complex. As a result, the cables inside the conduit must follow suit. We’re talking about ultra-fine wires, sometimes thinner than a strand of hair, but still must transmit power and data without breaking. It’s like trying to build a complete electrical system inside a straw.
3. Durability Under Pressure
These cables bend a lot. They get twisted, bent, sterilised and pulled. We incorporate strain reliefs, utilise highly flexible insulation, and thoroughly test everything to ensure it won’t fail during the procedure. At Romtronic, we conduct bend tests, pull tests, and cycle simulations to ensure our harnesses are built to withstand rigorous use.
4. Sterilisation-Ready
Whether steam, gas or radiation, these cables must be sterilised without failure. This means no melting, no outgassing and no degradation of performance. We choose materials that can withstand high temperatures.
5. Clean, Reliable Electrical Signals
Loss of signal in the conduit can mean missed heartbeats or critical diagnostic readings. That’s why we use shielding and quality insulation to block noise and maintain high signal integrity. We test for short circuits, leakage, and interference because accuracy is critical in healthcare.
The Engineering Challenges
Conduit design is not only small-scale, but also high-risk. Here are a few of the challenges engineers have to deal with:
- Tight spaces: Cables must be installed in very narrow conduits, often less than a few millimetres wide.
- Complex routing: Some conduit systems require dozens of wires for sensors, cameras or steerable tips. It’s like trying to fit a city’s power grid into a garden hose.
- Regulatory hurdles: Devices must be ISO, FDA and CE compliant. This means full traceability, risk management and documentation, with no room for guesswork.
At Romtronic, our engineers work closely with medical device teams to simplify these challenges. We provide Design for Manufacturing (DFM) input early in the process, which helps minimise redesigns and production delays later in the process.
What Romtronic Brings to the Table
For nearly three decades, we’ve been manufacturing custom medical cable harnesses for medical devices. Here’s what sets us apart:
- Certified Quality: We are ISO 13485 certified and comply with the IPC/WHMA-A-620 standard for cable assemblies. That means every step of the way is documented, traceable and verifiable.
- Clean Manufacturing: Our facilities are designed to meet the highest medical cleanliness standards, with 100% visual inspection and up to 300% testing of critical components.
- Custom Engineering Support: We don’t just manufacture products; we collaborate with our customers. From initial sketches to final testing, our engineers help optimise performance, reduce costs, and accelerate time to market.
- Scalable Production: Whether you’re prototyping or in large-scale production, we offer flexible yields, fast lead times, and consistent quality.
What’s Next? Trends & Innovations
The future of conduit cables is doing more with less:
- Smaller & Smarter: We’re seeing more and more “smart conduits” containing sensors, chips and even miniature cameras. The cables inside need to be powered and connected, all without adding bulk.
- Integrated Designs: Overmolded connectors and hybrid cable assemblies are becoming standard to reduce points of failure and speed up assembly.
- Greener Materials: There is a growing interest in sustainable, recyclable components that meet medical standards.
Romtronic stays at the forefront of these trends, investing in materials research, automation and flexible manufacturing technologies. Because in this industry, standing still means falling behind.
Final Thoughts
Biocompatible cable harnesses may be small, but they are a big responsibility. They must be safe, flexible and reliable, especially when lives are at stake. At Romtronic, we take this responsibility seriously. From choosing the right materials to ensuring optimal performance of each cable, we help medical innovators develop next-generation catheters and other products.
Have a project in mind? Let’s talk. Whether you’re refining an existing design or starting a brand new one, Romtronic is ready to help you connect the dots safely, intelligently, and at scale.
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
