Full Automatic Assembly Production Line For Reusable TENS & EMS Physiotherapy Electrodes

Published: JULY 27, 2026 - Shanghai Zhichen Medical Technology Co., Ltd.

Reusable TENS/EMS physiotherapy electrodes have unique production requirements such as carbon conductive printing, thick high-water-locking gel coating and repeated use lamination. The dedicated full-automatic assembly line integrates all core processes to realize unmanned mass production, stable product impedance and consistent gel thickness, which is the core production equipment for home rehabilitation electrode manufacturers.

1 Full Machine Standard Process Flow

Non-woven/PET substrate automatic unwinding & tension correction

Carbon conductive ink precision printing & low-temperature curing

Thick reusable hydrogel quantitative coating station

Silicone release liner automatic compound lamination

Multi-size rotary die cutting forming

CCD full visual appearance inspection

Single piece automatic stacking & counting

Manual auxiliary paper-plastic bag sealing packaging

2 Core Independent Station Technical Parameters

2.1 Carbon Printing Unit

Micro-adjustment printing scraper, uniform carbon film thickness tolerance ±0.01mm, low temperature hot air drying to avoid substrate deformation, ensure consistent surface resistance of finished pads.

2.2 Thick Gel Coating System

Dual storage constant temperature gel tank, large flow metering valve, gel thickness adjustable 0.3~1.2mm, suitable for high water retention reusable gel formula without bubble generation during coating.

2.3 Multi-Size Rotary Die Cutting Mold

Quick-change mold structure, compatible square, oval, butterfly TENS pad sizes, high hardness mold steel long service life, clean cutting without burrs.

2.4 Online CCD Inspection Module

Automatically identify missing carbon printing, gel shortage, substrate wrinkles, die-cut offset, automatically separate defective products without manual sorting.

3 Standard Production Capacity Reference

Single row standard line: 3200~4000 pieces per minute

Large-size thick gel TENS pad: 2600~3000 pieces per minute

Small mini rehabilitation electrode: up to 4500 pieces per minute

4 Cleanroom Matching Suggestions

The whole production line is suitable for 100,000-class constant temperature and humidity clean workshop, with independent dust removal air supply above printing and gel coating stations to prevent carbon powder and dust from polluting finished electrodes, complying with ISO13485 production environment standards.

5 Machine Operation & Daily Maintenance Key Points

5.1 Daily Shutdown Cleaning

Clean printing scraper and gel valve residual glue to prevent carbon ink and gel from solidifying and blocking precision parts.

5.2 Weekly Calibration

Substrate tension sensor, gel coating thickness encoder, die cutting position photoelectric switch calibration.

5.3 Quarterly Wear Parts Replacement

Printing rubber roller, coating compression roller, die cutting protective pad regular replacement to ensure finished product yield.

6 Customization Support For Production Line

Support single-row / double-row high-speed configuration switching, independent increase or decrease of printing, gel coating and inspection stations according to customer product structure, reserved space for automatic packaging machine docking to realize fully closed unmanned production.

Summary

Dedicated full-automatic TENS electrode production line solves the pain points of unstable resistance and inconsistent gel thickness in semi-manual production, greatly improves factory daily output and finished product qualification rate, and reduces long-term labor cost for rehabilitation electrode export manufacturers.