Why Tiny Gaps Matter: Testing and Designing Connectors over and over Again to Prevent Medical Errors

From concept to real-world application, Sunkye actively integrates customer feedback throughout the product development lifecycle, ensuring continuous optimization of connector functionality.

From Design to Deployment: A Continuous Improvement Process

Before connectors are approved for customer applications and market release, they undergo a comprehensive development process involving:

• Thoughtful material selection
• Precision size design
• Performance optimization
• Rigorous laboratory testing 

During this process, Sunkye leverages industry experience and customer feedback to refine connector structure and materials. This iterative approach ensures optimal performance while reducing the risk of costly redesign — not only for medical devices but also for other industries.

Designing with the Application Environment in Mind

A successful connector design must align with its intended application environment. Understanding customer needs is crucial for identifying key design requirements.

User Considerations in Medical Devices

Identifying the device’s end-user is essential in connector design:

• For professional medical staff: Precision, reliability, and efficiency are critical.
• For patients: Safety and ease of use become paramount.

The frequency of use is also a crucial factor, directly influencing the required number of mating cycles and overall durability.

In Vivo vs. In Vitro Applications

Connector requirements vary significantly depending on whether the device is:

· In vivo (inside the body):

o Stricter demands for size, weight, and material properties

o Focus on sealing integrity, biocompatibility, corrosion resistance, non-toxicity, and non-magnetic characteristics

· In vitro (outside the body):

o Durability, ease of cleaning, and user safety take precedence

Material Selection: Striking the Right Balance

Choosing the ideal material is not solely about selecting the “best-performing” option. Instead, the decision must balance performance, cost, and manufacturability — always guided by customer goals and practical outcomes.

For example:

· Niobium boasts superior corrosion resistance over titanium, making it highly suitable for long-term implants.

· However, niobium’s higher processing complexity, elevated costs, and limited industrial availability restrict its widespread adoption.

· As a result, titanium remains the preferred material for most implantable connectors due to its strong balance between performance, cost, and manufacturability.

Beyond Performance: The Power of Iterative Design

Connector design is not just about maximizing material performance or minimizing size and weight. Instead, it requires continuous refinement — integrating customer feedback, optimizing designs through repeated testing, and striking a balance between:

• Long-term reliability
• Cost control
• Manufacturability

This meticulous, customer-centric approach ensures minimal gaps between conceptual design and real-world functionality.

At Sunkye, we remain committed to designing and refining our connectors with precision, ensuring they meet the highest standards for safety, reliability, and performance — especially in critical medical applications where tiny gaps can make a big difference.