Project Summary

Client: OCTO

Product: Interconnection Cable for Removable Hard Drive Systems

Services: Cable & Interconnection Design, PCB Design, Overmoulding, Prototyping, Tooling, Manufacturing

Requirement: Replace a vulnerable standard cable with a robust, purpose-built interconnection capable of withstanding repeated handling while fitting within the system’s restricted internal layout and remaining compatible with the existing hardware.

Outcome: A reinforced cable assembly engineered around the system’s mechanical and spatial constraints, improving durability and reducing the likelihood of cable-related maintenance that previously required extensive equipment disassembly.

Project Benefits

  • Improved durability under repeated connection and handling.
  • Reduced risk of cable-related maintenance and equipment downtime.
  • Reliable routing through a restricted space and tight 90-degree bend.
  • Compatibility with OCTO’s existing hardware retained.
  • Production-ready design developed for repeatable manufacture.

Background

OCTO’s removable hard drive systems depended on an internal cable connection that was repeatedly handled during normal use.

The existing standard cable was not designed for the mechanical demands of the application and was susceptible to damage over time. The consequences of failure were disproportionate to the size of the component: replacing a damaged cable required significant disassembly of the computer system, resulting in additional maintenance time, labour and equipment downtime.

OCTO therefore needed a more robust interconnection specifically designed around the way the system was assembled and used, rather than another standard cable adapted to fit the application.

 

Requirement:

The new cable needed to withstand repeated connection, disconnection and mechanical handling while remaining fully compatible with OCTO’s existing removable hard drive system.

Space within the equipment was tightly constrained. The cable had to follow a fixed internal route and negotiate a sharp 90-degree bend, leaving little tolerance for additional bulk or uncontrolled movement. The design therefore had to combine flexibility with effective strain relief, protecting the areas most vulnerable to repeated mechanical loading without compromising fit or electrical performance.

The assembly also needed to:

  • Maintain compatibility with the existing hardware.
  • Withstand repeated connection and disconnection cycles.
  • Protect cable and connector interfaces from mechanical strain.
  • Resist abrasion during everyday use.
  • Integrate the required PCB and LED functionality.
  • Fit consistently within the available internal space.
  • Support repeatable manufacture and production testing.

Solution

DTI developed the interconnection as a complete purpose-built assembly, with the cable, connectors, reinforcement and PCB designed around the physical demands of OCTO’s system.

A high-flexibility overmould was developed around the critical 90-degree bend, enabling the cable to follow the required internal path while reducing stress at a point that would otherwise be vulnerable to fatigue. A durable outer sheath provided additional protection against abrasion and repeated handling.

The connector interfaces were reinforced with tailored overmoulding and bending supports to improve strain relief during repeated use. USB-C connectivity was retained to maintain compatibility with the existing system, while a bespoke PCB with integrated LED circuitry provided the required electrical connectivity and visual operating feedback.

Prototype assemblies were used to evaluate fit, bend behaviour and durability within the actual spatial constraints of the unit. Testing informed refinements to the overmould thickness, elbow flexibility and PCB mounting before production tooling was developed.

This iterative approach ensured the final assembly was not only mechanically robust, but could also be manufactured consistently and fitted reliably within the existing equipment.

Outcome

The completed interconnection addressed a recurring weakness within OCTO’s removable hard drive system by replacing a vulnerable standard cable with an assembly engineered specifically for the application.

Improved strain relief, reinforcement and cable routing reduced the likelihood of mechanical damage during repeated use. Because cable replacement had previously required extensive system disassembly, improving the durability of the connection also reduced the risk of avoidable maintenance intervention, equipment downtime and associated labour.

Crucially, these improvements were achieved without requiring OCTO to redesign the wider hardware platform. The new assembly fitted within the existing spatial envelope, retained the required connectivity and could be introduced as a production-ready component.

The result was a more resilient and maintainable system in which a small but critical component was far less likely to become the cause of disproportionate service disruption.

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