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Automated External Defibrillator (AED) Interconnect Solutions

As public access mandates drive broader AED deployment, OEM design engineers face growing pressure to meet stringent regulatory requirements while delivering highly reliable, compact and intuitive devices that are cost-effective and easy to deploy. To help address these challenges, Molex and Phillips Medisize offer connectors, cable assemblies, wire harnesses and flex circuits, along with human factors engineering and usability validation to support the development of reliable, intuitive devices. By enabling modular upgrades, improving readiness and minimizing late-stage changes that expand validation scope, these solutions help deliver manufacturable and serviceable AED platforms.

Optimizing AED Architecture for Improved Usability


AEDs present design engineers with unique challenges, as they must perform reliably in high-stress situations for untrained users. Engineers are tasked with balancing ease of operation, device readiness and future upgrades without requiring redesigns to help minimize late-stage changes and interconnect-related failures.

Meeting these objectives requires reliable power and signal transmission with electrical isolation, signal integrity and EMI protection, as well as modular architectures. Systems should offer intuitive layouts, guided routing and error-resistant connections with equal weight given to manufacturability and serviceability.

To support these design goals, Molex provides connectors, cable assemblies, flex circuits and electromechanical subassemblies engineered for signal integrity, production readiness and long-term performance.  Combined with expertise from Phillips Medisize in human factors engineering, usability validation, product development and precision injection molding, these technologies help prepare complex AED designs for production.

This end-to-end approach helps reduce integration risk and accelerate time to market, which can contribute to more user-friendly platforms with improved performance, streamlined validation and faster regulatory approval, while enabling future upgrades.


Power Supply and Battery Connectors


For AED design engineers, reliability of their life-saving devices is the top priority. Connectors play an important role in reliable product performance — they must protect against terminal damage during handling and mating processes while also reducing the likelihood of short circuits caused by debris infiltration. Molex connectors are engineered to address these critical concerns through robust positive latching mechanisms and fully isolated connector terminals.

Product Configuration Pitch Circuits Current Rating (max.)
ChargeStack Connectors Board-to-board 0.30, 0.35, 0.40mm 8 or 10 Up to 20.0A
Flexi-Latch+ Connectors FPC-to-board 1.50mm (single row)
2.00mm (dual row)
12 Up to 1.0A
Mega-Fit Connectors Wire-to-wire 
Wire-to-board
5.70mm 1 to 12 30.0A
Micro-Fit+ Connectors Wire-to-wire
Wire-to-board
3.00mm 2 to 22 Up to 10.5A
Micro-Fit Connectors Wire-to-wire 
Wire-to-board
3.00mm 2 to 22 10.5A
Mini-Fit Max Connectors Wire-to-wire
Wire-to-board
4.20mm 2 to 40 Up to 13.0A

Electrode Pad Connectors


Custom Cable Assembly Solutions

AED designs must comply with stringent industry standards and regulations. Through rigorous quality control protocols, Molex develops custom cable assemblies to meet demanding safety and performance requirements.

Custom I/0 Connectors

I/O connectors for AEDs must offer compatibility for physical connections and data transfer protocols. Phillips Medisize strictly adheres to all relevant industry standards and regulations that govern quality and safety requirements for I/O connectors, including IEC 60601.

Assemblies and Secondary Manufacturing

Effective assembly and manufacturing processes are critical to end-product performance. Phillips Medisize brings decades of experience and established quality management systems for advanced manufacturing — including certified clean rooms for processing and assembly — to ensure consistent and reliable production of high-quality AEDs.

High-Voltage Power System Connectors


Power systems in AEDs must be highly efficient to ensure optimal use of energy, maximizing the number of shocks that can be delivered on a single charge. Engineers are tasked with minimizing power losses and optimizing energy transfer to support reliable power delivery in emergency situations. Molex enhances the efficiency of these power systems with connectors that offer high-current capacity and robust locks for secure mating, all in a compact package. 

  Configuration Pitch Circuits Max. Current Rating
Mega-Fit Connectors Wire-to-wire
Wire-to-board
5.70mm 2 to 22 30.0A
Micro-Fit Connectors Wire-to-wire 
Wire-to-board
3.00mm 2 to 22 10.5A
Mini-Fit Sr. Connectors Wire-to-wire
Wire-to-board
10.00mm 2 to 14 Up to 50.0A
Super Sabre Connectors Wire-to-wire
Wire-to-board
7.50mm 2 to 8 Up to 34.0A
Ultra-Fit Wire-to-wire 
Wire-to-board
3.50mm 2 to 16 14.0A

Patient Monitoring and ECG Connectors


To support critical AED functionality for advanced monitoring and efficient data transfer, designers must incorporate robust and reliable connections. Molex connectors are designed with positive locking, keying and polarization features that help prevent mis-mating during the assembly process.

  Current Pitch Wire AWG
Standard .093” Pin and Socket Connectors up to 17.0A 5.03, 6.30 and 6.70mm 14 to 22

Custom Pin and Socket Connectors

To enable specialized AED monitoring and data transfer capabilities, Phillips Medisize offers custom pin and socket connector solutions that help avoid mis-mating and deliver consistently reliable connections between sensors and the device.

User Interface Connectors


The user interface (UI) of an AED device must support ease of use and withstand potentially harsh environmental conditions. At the same time, UI components need to provide design flexibility and optimize space. To meet these requirements, Molex offers innovative and durable UI solutions available in a broad range of configurations — including 2 to 42 circuits, single or dual row and vertical or horizontal plugs.

  Configuration Pitch Circuits Max. Current Rating
FFC/FPC Connectors Flex-to-board 0.20 to 2.00mm 2 to 120 Up to 2.0A
KK Plus Connectors Wire-to-board 2.50mm
3.00mm
3.96mm
2 to 8 11.0A
Micro-Fit+ Connectors Wire-to-wire
Wire-to-board
3.00mm 2 to 24 13.0A
Micro-Latch Connectors Wire-to-board 2.00mm 2 to 15 2.5A
Micro-Lock Plus Connectors Wire-to-board 1.25mm
2.00mm
2 to 42
2 to 16
3.6A
4.7A
Micro-One Connectors Wire-to-board 2.00mm 2 to 8 4.0A
Mini-Lock Connectors Wire-to-board 2.50mm 2 to 15 3.5A
Nano-Fit Connectors Wire-to-board 2.50mm 2 to 16 8.0A
PicoBlade Connectors Wire-to-wire
Wire-to-board
1.25mm 2 to 15 1.0A
Zero-Hachi Connectors Wire-to-board 0.80mm 2 to 30 Up to 2.5A

User Interface Solutions

Molex offers a collaborative approach to design, focusing on user-centered feedback and incorporating valuable visual cues in customized interface solutions for each unique application.

Custom Cable Assembly Solutions

Incorporating connections in AEDs for external devices or accessories requires design flexibility to support a range of connectors, ports and interfaces. Molex offers custom cable assembly expertise and designs to help engineers explore options and select components that meet specific connection requirements for the device.

USB Type-C Connectors

AED design engineers need a standardized, high-speed interface for device servicing, software updates, diagnostics and power delivery without adding complexity or increasing validation risk.

Main Electronics Connectors


AEDs are designed to be portable and lightweight for easy transport and use in various settings. To meet portability requirements, design engineers need connectors that occupy minimal space, contributing to a more compact device. Molex offers a variety of miniaturized connectivity solutions, including the world’s smallest board-to-board connector, which are ideally suited for space-constrained devices like AEDs.

  Configuration Pitch Circuits Max. Current Rating 
Quad-Row Connectors Board-to-board 0.175mm 32, 36 3.0A

SlimStack Connectors

Board-to-board 0.35mm to 1.25mm 6 to 240 18.0A
Pico-Clasp Connectors Wire-to-wire 
Wire-to-board
1.00mm 2 to 50 2.0A

CLIK-Mate Connectors

Wire-to-board 1.25, 1.50 and 2.00mm 2 to 34 1.25mm pitch: 2.5A 
1.50mm pitch: 3.0A 
2.00mm pitch: 4.0A
Micro-Lock Plus Connectors Wire-to-board 1.25mm 
2.00mm
2 to 42 
2 to 16
3.6A 
4.7A
Micro-Fit Connectors Wire-to-wire
Wire-to-board
3.00mm 2 to 22 10.5A
Mini-Fit Connectors Wire-to-wire
Wire-to-board
Board-to-board
4.20mm 2 to 24 20.5A
Micro-Latch Wire-to-board 2.00mm 2 to 15 4.5A

Communications and Memory Connectors


Communication and memory functions are vital aspects of AEDs for capturing, transmitting and storing shock data and timestamps following usage. Enabling rapid and reliable data transmission to healthcare providers requires connectivity solutions with strong signal integrity to help prevent data corruption, error or loss. Molex 5G and memory card connectors support data transfer, compatibility and reliability requirements for AEDs with full EMI shielding for exceptional signal integrity.

  Configuration Frequency
5G mmWave RF Flex-to-Board Connectors Signal: 2 to 4 
Ground: 4 to 6 
Power: 4 to 0
15 GHz 
25 GHz
  Circuits Ejector Style
Memory/SIM Card Connectors 6 to 9 Push – push, hinge