Complete Device & Subassembly
Complete Device & Subassembly
Where every capability comes together.
Most complex devices draw on multiple engineering areas at once. This is where those areas come together, as a complete device or as a subassembly for a larger system, with documented, validated assembly processes. Because ATL Medical designs and manufactures the connector, cable, PCBA, molded components, and catheter shaft in-house, integration is the final step in one internally owned process, not a handoff between vendors. ATL Medical performs critical plastic injection molding for device handles, connectors, and other components, integrating molded parts with interconnects, electronics, catheter technologies, and final device assembly.
What this capability covers.
Complete device assembly
Electronic, optical, and mechanical subsystems brought together into one finished device.
Subassemblies for larger systems
Camera-based subassemblies, navigation-enabled distal assemblies, and articulating shaft components for robotic surgical platforms.
Validated assembly processes
Documented, repeatable assembly processes for complex multi-subsystem devices.
Components made in-house
Injection-molded handles and connectors, cable, PCBA, and catheter shaft, all built under one roof before assembly.
Developing an integrated electrosurgical platform.
The challenge. A surgical platform needed to combine energy delivery, mechanical tissue resection, and wired and wireless controls in one system.
What ATL Medical did. ATL brought those subsystems together into one integrated platform and drove integration through verification and compliance testing.
Capabilities involved: Energy & Electronics Systems · Complete Device & Subassembly
Technical depth.
What does "integration" mean in practice at ATL Medical?
Manual and automated complete-device assembly; pin insertion; cutting, stripping, crimping, and fine soldering; laser, ultrasonic, RF, pulse, and hot-bar joining processes where applicable; heat staking; image inspection; electrical and functional testing; PCB programming; conformal coating; and cable coiling. The applicable processes depend on the device and program scope.
Why does in-house component manufacturing matter for integration?
ATL's engineering team designs and manufactures the connector, cable, PCBA (in-house SMT), handle, other molded components, and catheter shaft, then assembles them into one device. Because every piece is built under the same roof, integration doesn't depend on managing tolerances and handoffs across multiple outside vendors.
What molding capability supports the molded components in an assembly?
Horizontal and vertical molding, insert molding, cable and connector overmolding, single-shot and two-shot/dual-material molding, low-pressure molding, liquid silicone rubber molding, and micromolding—supported by injection-molding DFM, tool design review, modular and bridge tooling, and first-article/qualification support.
What kinds of devices need this capability?
Multi-subsystem devices, capital equipment, complex disposables — any device requiring true cross-capability integration rather than a single-point solution.
How does this differ from Automation & Scalable Manufacturing?
Complete Device & Subassembly focuses on bringing subsystems together into a validated device; Automation & Scalable Manufacturing focuses on producing that device at scale. They frequently work together on the same program.
Related markets and capabilities.
Have a multi-subsystem device?
Talk to an ATL Medical engineer about your program.