Find ISL Products Online at 
9V Battery Charger for T.E.N.S Machines
A 9V Battery Charger designed to be used specifically with T.E.N.S machines. Its slim line profile and unique case make it easy to use.
Overview
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.
Challenge
We had to design this battery charger for multiple rechargeable 9V 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.
Solution
ISL agreed to tool for and manufacture the 9V battery charger 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.
Conclusion
ISL stepped in to tool and manufacture a 9V battery charger for T.E.N.S. machines after the customer's previous supplier could no longer support their lead time and volume pricing needs. By securing UL and CSA safety approvals and matching the plastic housing color while preserving the charger's slim profile and pop out hole design, ISL delivered a product that met every consumer safety and usability requirement. Agreeing to hold and release inventory against a blanket purchase order also cut the customer's lead time significantly while lowering their unit cost. This project shows how ISL can rescue a supply chain gap and turn it into a dependable, cost effective manufacturing partnership.