Retractile Cord with Custom Grommet

A customer in the medical field recently came to us requesting a custom retractile cord with a 9 Pin D Sub Connector.

With our years of experience creating medical-grade cords, Consolidated was a perfect fit to take on the contract.

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Our technicians developed the cord to meet all of the stringent standards required for manufacturing in the medical industry. It was custom tooled, manufactured, and 100% color matched to meet our customer’s specifications.

Its specially designed grommet was over molded with a polyurethane jacket and featured an external and an internal end for a custom fit. The completed cord measured 12” retracted and 35” extended.

To ensure the highest quality, every cord was 100% electrically and spark tested to relevant UL standards. Our team manufactured a total of 5,000 custom retractile cords for delivery to our customer’s locations in Illinois and China—all within a production turnaround lead time of just 3-4 weeks.

Retractile Cord Project Details

Project Name & Description

Retractile Cord with 9 Pin D Sub Connector

Capabilities Applied/Processes

Cable manufacturing – inner conductors, individual copper strands (1/4” dia copper rod drawn, then cabled/twisted), coated/extruded. Place on reel, twist, extrude, cut to length, coil to i.d. specs, strip jacket, strip wires to expose bare copper to mold connector on end. Custom over molding, strain relief (alleviates tension at end of cable to ensure coated cords do not pull out of connector end).

Equipment Used to Manufacture Part

Extruder, Unwinder, Injection Mold Machine, Automated Winder, Cord Curler/Rewinder

Overall Part Dimensions

12” Retracted and 35” Extended

Material Used


Industry for Use


In Process testing/Inspection Performed

100% Electrically Tested, Spark Tests



Delivery/Turnaround Time

3–4 weeks

Delivery Location


Standards Met



Contact us today to learn more about this project or to find out how we can put our custom cord manufacturing capabilities to work on your next project.