A headlight assembly needed to be low cost and fit within envelope constraints. We had the solution.

Cost reduction
Engineering resources
Circuit boards

The problem

A headlight assembly for a medical mobility OEM needed to be low cost and fit within specific envelope constraints. However, the initial design included rigid injection molds which were expensive. Even worse, additional assembly was required after molding.

Our solution

Global Interconnect partnered with the customer’s engineers to develop a low-pressure molding design that would encapsulate the board without damaging the electronics. In addition, we were able to achieve the complex geometry required to fit into the upper level assembly without any additional assembly steps.

The result

Global Interconnect manufactured and validated the headlight assemblies, meeting all performance and cost goals.

Products Key to this Case Study


We manufacture assemblies that connect medical devices or industrial consoles to surgical handpieces or measurement devices when off the shelf configurations are not available. Reusable or disposable, these include custom electrical able, tubing, or a combination of both using thermoplastic and thermoset materials.


We’re experts at producing low cost vertical and horizontal injection molded thermoplastic and thermoset materials smaller than a shoebox.


We manufacture CNC machined custom components from plastic or metal rod stock.


We manufacture medical and industrial electromechanical assemblies requiring labor intensive or automated assembly processes, testing, and documentation in a controlled, ISO certified facility.


You won’t find what we offer in a catalog, but you will find it invaluable. Especially when you’ve got a problem in need of a solution.