OEM Digital TENS Unit | Dual-Channel PCBA | TOP-RANK
B2B digital TENS hardware. Engineered with independent output transformers and MCU-driven pulse width modulation for precise clinical pain gating.
Product Overview
This digital TENS unit is a dual-channel pulse generator utilizing a microcontroller unit (MCU) to manage waveform output. It replaces traditional analog potentiometers with a digital interface and an LCD feedback screen. The core PCBA steps up standard 3.7V Li-Po or 9V DC input into controlled, asymmetrical biphasic electrical pulses directed through physical lead wires. We supply this assembled hardware and programmed firmware to B2B rehabilitation equipment distributors and OTC pharmacy chains.
Key Features
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Microsecond Pulse Width Modulation
Analog dials suffer from mechanical drift and carbon track wear, leading to output degradation over time. This digital architecture locks the pulse width and frequency parameters using firmware-level coded instructions. The MCU generates precise square waves, allowing clinicians to set exact microsecond intervals. The output remains mathematically flat across the entire therapy cycle without analog fluctuation.
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Dual-Channel Magnetic Isolation
Non-isolated circuits allow stray current to jump between Channel 1 and Channel 2, creating hazardous cross-chest vectors if pads are misplaced. The PCBA in this unit mounts two independent step-up transformers. The electrical load for each channel is magnetically separated at the hardware level. Current dispatched from the left port cannot physically return through the right port.
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Constant-Current Closed-Loop Topology
As the patient's skin hydrates from sweat during a 45-minute session, the epidermal resistance drops. A voltage-based machine will inadvertently spike the current, causing focal shocks. This hardware utilizes a closed-loop feedback circuit that continuously measures the real-time impedance across the hydrogel pads. The MCU instantly adjusts the internal voltage rail to maintain the exact milliampere (mA) level selected on the LCD.
Applications
Clinical Pain Clinics
Programmable hardware for standardized physical therapy protocols requiring exact parameter replication.
Post-Surgical Discharge Kits
Locked firmware settings to prevent patient tampering during unmonitored at-home recovery.
OTC Pharmacy Distribution
Retail-ready boxed units complete with hardware, standard 2.0mm lead wires, and consumable hydrogel pads.
OEM & Private Label
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Firmware Customization: Pre-set therapy modes, LCD segment layouts, maximum amplitude lockouts, and default timer constraints are programmed at the MCU level during initial SMT runs.
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Logistics Routing : PCBA fabrication, firmware flashing, and plastic injection molding operate in China. Final device assembly, LCD installation, functional QA, and retail packing are routed through our Vietnam facility to manage global trade tariffs and build supply chain resilience.
Certifications
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Regulatory: Electrical schematics and firmware validation files support OEM submissions for FDA 510(k) Class II and CE (MDR) compliance.
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Systems: PCB insertion, final assembly, and QA batch testing execute under audited ISO 13485:2016 protocols.
FAQ
Q: Can the digital screen display the exact remaining battery percentage like a smartphone?
A: Standard segmented LCDs rely on voltage drop thresholds to trigger a basic low-battery icon. Displaying an exact percentage requires a dedicated battery management IC (fuel gauge) and a dot-matrix screen. Adding these components alters the PCBA footprint and increases the unit's baseline power consumption.
Q: Why does the device automatically reset the intensity to 0 mA when the user changes modes?
A: This is a firmware-level safety interlock. Different therapy modes utilize varying pulse widths. A 50mA intensity that feels comfortable at a 50-microsecond width will cause a severe, painful shock if the mode switches directly to a 250-microsecond width. The MCU zeroes the output transistors during any mode transition to force manual amplitude recalibration.
CTA
B2B hardware distributors and physical therapy brands can request PCBA functional prototypes and firmware specification matrices.
👉 [Request Digital TENS Prototypes]
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Specifications
| Parameter | Metric Configuration | Engineering Detail |
| Channels | Dual Isolated | Independent magnetic transformers |
| Output | 0 - 100 mA | Measured at 500 Ohms load |
| Pulse Width | 50 - 300 Microseconds | MCU coded intervals |
| Frequency | 1 - 150 Hz | Digital square wave synthesis |
| Display | Segmented LCD | Real-time parameter feedback |
