EMPI StimCare Premium Electrodes

Discontinued product notice: EMPI StimCare Premium electrodes are no longer manufactured. They will not be restocked.

For the four original StimCare Premium sizes, the closest premium replacement is the Uni-Patch Starburst Electrode line. Starburst electrodes are available in the same principal shapes and dimensions and use a silver current-distribution design, a conductive carbon-film base, thick aloe hydrogel, and reusable pigtail construction.

Customers seeking a lower-priced everyday replacement may also compare the following:

• Balego TENS/NMES/FES Electrodes
• Uni-Patch R Series Electrodes
• Uni-Patch Classic Electrodes
• 696SS Superior Silver Blue Gel Electrodes
• Balego’s full Electrotherapy Electrode collection

Read the related guide: EMPI TENS Pads Replacement: Starburst Electrodes.

Starburst electrodes are not EMPI-branded products. They are the closest current premium replacement based on the following:

• Matching sizes and shapes
• Silver-based current distribution
• Aloe hydrogel
• Four electrodes per package
• Reusable construction
• Pigtail-style lead-wire connection

The Starburst line is coming from the same manufacturing facility known for EMPI-style electrode quality. (Balego)

EMPI StimCare Premium electrodes were reusable self-adhering electrotherapy pads for compatible TENS and NMES systems. Their distinguishing features were conductive silver ink that spread electrical current across the electrode surface, thick aloe-based gel, repeat-use adhesion, a two-sided storage liner, and construction that EMPI described as latex-free.

Because electrode hydrogel is consumable, owners of otherwise functional EMPI units eventually need a current-manufactured replacement, even if the stimulator itself continues to work.

Starburst Electrodes are designed for compatible TENS, NMES, EMS, and FES equipment and are sold in the same four main sizes formerly offered in the StimCare Premium family.

The Starburst gradient uses silver ink over a carbon-film base to help distribute stimulation outward across the electrode.

EMPI 199657-001 — 2" round

Recommended replacement: Starburst 2" Round, Model 627SB / EP85340

The round shape is useful on curved or compact treatment regions where square corners may lift or feel awkward. The current Starburst model maintains the same nominal 2-inch diameter and four-pad package format as the discontinued EMPI electrode.

Other choices:

• Balego 2" Round Electrodes for American-made everyday replacement pads
• Uni-Patch R Series 2" Round for an economical tricot-backed option
• DURA-STICK PLUS 2" Round for clinic case purchasing

Recommended replacement: Starburst 2" Square, Model 616SB / EP85345

The 2-inch square is the most versatile replacement size for many general TENS and NMES placements. It offers the same nominal dimensions as EMPI 199658-001.

Other choices:

• 696SS Superior Silver Blue Gel Electrodes for a skin-friendly 2" square silver/carbon pad
• Classic 2" × 2" Electrodes for soft foam and aloe hydrogel
• Balego 2" Square Electrodes for an American-made value option
• InTENSity 2" Square Electrodes, 40 Pack for bulk replacement inventory

Recommended replacement: Starburst 2" × 4" Rectangle, Model 617SB / EP85360

The rectangular option provides broader contact over larger muscles or treatment regions such as the thigh, hip, shoulder, or back. It matches the nominal size and shape of the discontinued EMPI 199659-001.

Other choices:

• Classic 4" × 2" Rectangle
• Uni-Patch R Series 2" × 4" Rectangle
• DURA-STICK PLUS 2" × 4" Oval when rounded edges are preferred

Recommended replacement: Starburst 2.75" Round, Model 628SB / EP85350

This larger round pad offers broader surface contact while retaining rounded edges. Its nominal dimensions match the discontinued EMPI 199660-001.

Other choices:

• Balego 2.75" Round Electrodes
• Uni-Patch R Series 2.75" Round
• Classic 2.75" Round Electrodes

This model belonged to EMPI’s carbon-cloth electrode range. It used a breathable cloth backing and an anchored pigtail rather than the StimCare Premium silver-and-aloe construction.

There is no exact current Starburst equivalent.

Closest compact round option: Balego 1.25" Round TENS/NMES/FES Electrodes

Closest current back-focused alternatives:

• Advantrode Elite 4" × 6" Butterfly/Paravertebral Electrode
• Advantrode Elite 1.5" × 13" Backlasp Electrode
• Starburst 2" × 4" Rectangle Electrodes when separate conventional pads are acceptable

Advantrode Elite back electrodes use silver/carbon conductive film, 35-mil hydrogel, flexible foam, and molded lead-wire connections, but they are functional alternatives, not exact replacements.

Electrode compatibility has two separate parts:

1. The lead wire must fit the EMPI device.
2. The electrode end of that lead wire must fit the replacement pad.

Many legacy EMPI safety lead wires have an EMPI-specific device connector at one end and standard 2 mm pin-style electrode plugs at the other. In that setup, a current pigtail electrode designed to accept 2 mm pins can often be used without replacing the EMPI lead wire.

Do not purchase a pad based only on the EMPI brand name. Compare the physical connector with the replacement electrode or consult Balego customer service.

Our TENS Electrode Buying and Compatibility Guide provides additional guidance on matching pigtail pads, 2 mm pins, lead wires, sizes, and device connections.

A new electrode will not correct a cracked, loose, or intermittent lead wire.

We currently carry selected EMPI safety replacement lead wires for compatible legacy devices. Device-side EMPI connectors vary, so confirm the stimulator model and original lead-wire number before ordering.

Do not substitute the general 45-inch TENS/NMES lead wires unless the 2.35 mm device-side plug matches the unit. Their electrode ends use standard 2 mm pins, but their device connection is not universally compatible with EMPI equipment.

When switching electrode products:

1. Turn the stimulator off and reduce both channels to zero.
2. Match the old pad’s size and shape as closely as practical.
3. Confirm the replacement accepts the lead wire’s pin connector.
4. Apply it to clean, dry, intact skin.
5. Begin again at zero intensity.
6. Increase the output gradually.
7. Do not assume the old intensity setting will feel identical.

A replacement pad can feel different because hydrogel thickness, conductor design, surface area, adhesion, and current distribution vary between electrode lines.

At the same device setting, a smaller electrode generally concentrates stimulation over less skin area, while a larger electrode spreads it across more surface area. Balego’s electrode guide therefore recommends matching the original dimensions whenever possible and readjusting intensity after any size change.

Current replacement pads should be used according to their packaging and the electrotherapy-device instructions.

• Apply only to clean, dry, intact skin.
• Remove lotion, oil, sweat, and topical medication.
• Handle the electrode by its backing or edge.
• Do not pull it from the skin by the pigtail wire.
• Return it to its protective liner after treatment.
• Store it inside the resealable pouch.
• Assign reusable pads to one person.
• Replace a pad when it dries, curls, becomes contaminated, loses adhesion, or produces uneven stimulation.
• Do not add conductive gel to a pre-gelled self-adhering electrode unless its instructions specifically permit it.
• Do not cut an electrode into a different size.

We maintain current replacement options for owners of legacy EMPI equipment instead of directing customers toward expired or unsupported electrode stock.

Customers can:

• Shop Starburst Premium Electrodes
• Compare American-Made Balego Electrodes
• Compare Uni-Patch R Series Electrodes
• Compare Classic Aloe Hydrogel Electrodes
• Shop 696SS Blue Gel Electrodes
• Browse all Electrotherapy Electrodes
• Review the EMPI TENS Pad Replacement Guide
• Read the TENS Electrode Buying Guide
• Contact Balego for legacy connector and item-number assistance