Case Study: 9V Battery Charger for T.E.N.S Machines
ISL was approached by a company who manufactures T.E.N.S. machines (Muscle stimulator machines used for physical therapy). They needed a unique 9V battery charger for their application. We were asked to manufacture this product because their current supplier, a major Japanese manufacturer, refused to stock inventory of the item causing lead times to reach upwards of 18 weeks. The customer was also having issues with price breaks for high volume quantities.
We had to design this battery charger for multiple rechargeable battery chemistries. The previous manufacturer was the only company who was manufacturing chargers like this at the time. The charger also needed to be consumer proof, ensuring the battery wouldn’t overcharge. The other two features that make this product unique are the slim line profile and the hole in the plastic housing. The hole in the housing allows the user to easily pop the battery out of the charger.
ISL agreed to tool for and manufacture the product as well as underwrite the safety approvals. We provided UL and CSA markings. We were able to color match the plastic housing for the customer as well as keep the slim profile and the unique hole in the charger housing.
Additionally, ISL agreed to hold and release inventory against a blanket PO. This helped reduce the lead time and lower the customer’s unit cost. We currently manufacture and supply this product in high volume.