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High-Voltage Interconnects for Medical Devices

Caton designs and manufactures custom high-voltage cable assemblies for medical capital equipment — diagnostic imaging, radiation therapy, sterilization systems, electrosurgery, and neuromodulation platforms. We are a low-volume, high-complexity specialty supplier built for custom HV engineering, not for high-volume disposable assemblies. Engineering-led since 1973.

AS9100 ISO 9001 UL 94 V-0 Custom HV engineering Low-volume / high-mix
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What we do

Custom high-voltage interconnect for medical capital equipment

Caton serves medical OEMs and the high-voltage power supply manufacturers who supply them, on programs where the interconnect is custom-engineered rather than catalog-selected, where volume is measured in dozens to hundreds rather than thousands, and where the assembly carries enough HV stress that off-the-shelf parts won't qualify. Our engineering and quality leadership came up in the medical industry. Our quality system is AS9100, which carries the same risk-based design control and traceability backbone that medical capital equipment programs run on.

We do not build high-volume disposable medical assemblies, and we do not pursue patient-contact device work. We build the high-voltage assemblies inside the cabinet — accelerator power conditioning, RF and HV delivery to surgical generators, neuromodulation pulse delivery, and the custom HV interconnect that imaging, therapy, and sterilization platforms require.

Engineering capability

High-voltage engineering aligned to medical capital equipment

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Custom HV interconnect engineered for the cabinet, the modality, and the regulatory regime. Multi-conductor signal and power assemblies, overmolded HV terminations, and precision connector geometries — all designed under AS9100 controlled processes by an engineering team with medical industry experience.

Capability
High-voltage design, in-house

Custom cable and connector design from 1 kV to 250 kV. Finite element analysis using Electro V10.2 for electric field optimization, corona mitigation, and dielectric stress analysis. Materials selection driven by application and regulatory environment, not catalog availability.

In-house overmolding

Overmolded HV terminations engineered for the application — not adapted from commercial parts. Overmold geometry, materials, and processing are part of the electrical design, including for assemblies subjected to repeated cleaning, sterilization cycles, and long service life.

Capability
Test capability on-site

Corona inception and extinction, partial discharge, hi-pot, insulation resistance, dielectric withstand, leakage current, and thermal cycling — all in-house. Altitude testing to 70,000 ft in our Tenney altitude chamber. Manufacturing engineers work at benches on the production floor, alongside the test stations and the build, so design issues get caught and resolved in real time.

Quality system aligned with medical industry practice

AS9100-certified quality management system. Risk-based design control, full traceability, locked configurations, and serialized build records. AS9100 and ISO 13485 share substantial common ground — risk-based thinking, design control, configuration management, supplier control. Caton's engineering and quality leadership came up in the medical industry and built the QMS to support medical capital equipment programs.

Capability
Materials engineered for medical service

PEEK insulators for high-temperature and sterilization-tolerant service. FEP-jacketed cable for chemical resistance and dielectric stability. Silicone overmold for HV termination geometry. UL 94 V-0 flammability ratings on cable jacket and overmold materials.

Configuration control across the program lifecycle

Medical capital equipment platforms run for ten to twenty years in the field. Locked configurations, controlled change management, build records archived for the life of the program. The assembly qualified at design release is the same assembly built in year fifteen.

Programs and applications

Where Caton interconnect fits in medical capital equipment

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High-power accelerator-based medical and sterilization systems — HV interconnect for diagnostic X-ray imaging, radiation therapy (linear accelerators, brachytherapy afterloaders), and electron beam / X-ray sterilization platforms. HV power conditioning, beam steering and monitoring, and accelerator integration assemblies.
Electrosurgery and ablation systems — RF power delivery, HV ignition for surgical generators, and energy delivery interconnect for surgical handpieces and ablation systems.
Neuromodulation and pulse therapy systems — HV pulse delivery and patient-applied energy interconnect for transcranial magnetic stimulation, neurostimulation, and related therapeutic modalities.
Clinical and analytical mass spectrometry — HV interconnect for ion source power, detector bias, and analyzer voltages on diagnostic and clinical mass spec platforms.
High-voltage power systems for medical capital equipment — Caton ships into medical capital equipment programs via the HV power supply manufacturers serving the segment, including assemblies that integrate into imaging, therapy, and instrumentation platforms.
Custom HV interconnect for medical research and instrumentation — purpose-built assemblies for clinical research, drug discovery instrumentation, and emerging therapeutic platforms requiring HV engineering not available from catalog suppliers.
Engineering posture in the medical market

A specialty supplier built for custom HV engineering — not for high-volume disposables

Caton serves the medical market as an engineering-first specialty supplier. We engage directly with medical capital equipment OEMs on programs where the high-voltage interconnect requires custom engineering, and we ship into medical end-use through tier-1 HV power supply manufacturers who serve imaging, therapy, and sterilization platform OEMs. Either path leads to the same engineering bench.

The programs we're built to engage:

New medical capital equipment platforms in development, where the HV interconnect is being designed and qualified.
Sustainment and obsolescence recovery on fielded platforms where the original supplier can no longer build, qualify, or support the assembly.
Custom HV interconnect for medical research, clinical, and analytical instrumentation that does not fit catalog parts.
HV power supply manufacturers needing engineered cable and connector assemblies for medical end-use.

We are not built for high-voltage disposable medical assemblies, patient-contact device work, or commodity connector supply. The engagement is engineering-led, the volume is dozens to hundreds, and the relationship is direct.

Why medical OEMs work with Caton

Custom HV engineering, low-volume / high-mix, and engineering accountability

Reason
Custom HV engineering, not catalog selection

Medical capital equipment HV interconnect rarely fits a catalog connector. Caton designs the assembly to the application: corona-free at the operating voltage, geometries that integrate into the cabinet, materials selected for the regulatory environment.

Built for low-volume, high-mix programs

Medical capital equipment programs ship in dozens to hundreds, not thousands. Caton's low-volume, high-mix model is built for that scale — without the per-unit overhead of a high-volume contract manufacturer or the inflexibility of a catalog vendor.

Reason
Engineering response is direct

Your design engineer talks to our design engineer. The answer comes from the person who can change the design, not from an account manager who has to check with engineering and call you back.

Configuration control for ten- to twenty-year program life

Medical capital equipment platforms stay in the field for decades. Locked configurations, controlled change management, and same-team engineering since 1973 mean the assembly qualified at design release stays available, identical, and engineering-supported through the program lifecycle.

Engagement

Working with Caton on a medical capital equipment program

We're built for the design phase of new medical capital equipment platforms and for the recovery or sustainment phase of programs where the incumbent supplier can no longer build, qualify, or support the HV interconnect. We respond to RFQs at the development, qualification, and production stages, and we support sustainment, obsolescence management, and configuration recovery on legacy platforms. We are a specialty HV engineering supplier — not a high-volume disposables manufacturer.

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Talk to engineering about your medical capital equipment program

Your design engineer talks to our design engineer. New platform development, qualification recovery, sustainment, or obsolescence management on fielded medical equipment — the conversation starts at the engineering bench.

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