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Revolutionizing Medical Devices with High-Density D04 Connectors

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In the fast-evolving world of medical devices, innovation knows no bounds. Smiths Interconnect has once again raised the bar with the introduction of their groundbreaking D04 connectors, a high-density addition to their renowned D connector series tailored for the medical market segment. These connectors promise a game-changing blend of high contact density, exceptional cycle life, and ease of assembly. The demand for high-density electrical connectors in medical devices has been steadily on the rise. Several factors are fueling this surge, primarily the imperative need for medical devices to be smaller, lighter, and more functional. With the growing popularity of portable and patient-wearable devices, the size and weight of connectors have suddenly taken center stage in the medical sector.

The Power of High Density

One of the key advantages of high-density connectors is their ability to pack more functionality into smaller spaces. With connectors like the D04, design engineers can enhance device performance without compromising on size and weight. This enables critical medical devices to remain ergonomic and easy to operate for healthcare providers, a pivotal aspect in the medical field. Applications that require high-density electrical connectors are numerous. Electrophysiological mapping and ablation of arrhythmias, intravascular and cardiac imaging, and many other high-performance medical tasks now have a reliable ally in the form of the D04 connector.

The D04 Advantage

Smiths Interconnect’s D series was already a stalwart in the industry, available in two standard sizes with contact counts ranging from 3 to 25. Now, with the introduction of the D04 connectors, this series has been supercharged to offer an impressive high-density configuration. The D04 can support a high contact count and boasts an incredible cycle life of up to 10,000 cycles. One of the standout features of the D04 connector is its pin and socket configuration, which ensures an insulation resistance greater than 5000 MOhm at 500 VDC. This remarkable performance aligns with the stringent electrical requirements of EIA-364-05 to 70 Test Procedures set by the Electronic Industries Alliance. Moreover, the D04 employs low-resistance pin and socket technology, a clear advantage over its spring probe counterparts.

Meeting Critical Medical Needs

Mark Kelleher, VP and General Manager of the Connectors Business Unit at Smiths Interconnect, emphasizes the significance of the D04 connectors in addressing the needs of critical medical applications. He points out that the high-density solution featuring 82 contacts specifically caters to ablation catheters. This is a remarkable feat as there was previously no comparable competition in the market for such applications.

The D04 connectors have been designed and rigorously tested to offer a range of benefits:

  1. High Density Standard: With 82 positions as standard, these connectors stand head and shoulders above the competition in critical medical applications.
  2. Touch-Proof Design: The push-button quick disconnect and finger-proofing isolator ensure safety and reliability, a paramount concern in medical settings.
  3. Ease of Assembly: The D shape layout of the connector and receptacle housings significantly reduces the possibility of incorrect mating, making assembly a breeze.
  4. Ergonomics: These connectors are engineered for one-handed mating and de-mating, streamlining the workflow for healthcare professionals.
  5. Confidence in Testing: Manufacturers can have high confidence in the qualification testing of the D04 connectors, ensuring the reliability of their devices.

Furthermore, custom solutions can be tailored to the specific needs and specifications of individual devices, offering support for over 120 contact positions.


The introduction of the D04 connectors by Smiths Interconnect marks a significant milestone in the medical device industry. These high-density connectors are set to revolutionize medical device design, offering a potent combination of performance, reliability, and ease of use. As the demand for smaller, lighter, and more functional medical devices continues to grow, the D04 connectors are poised to play a pivotal role in shaping the future of healthcare technology.

D04 Connectors

D Series Connectors

D Series delivers industry-leading performance featuring simple push-button latching and a "D" shaped flange which makes mating orientation obvious. There are three D Series sizes that accommodate a wide variety of applications.. Intuitive and durable D Series is recognized for its ease of use and high reliability. 

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