Cable Assembly Capabilities

Custom Cable Assembly Manufacturing

Complex custom cable assembly solutions for automotive, medical, industrial, and robotics applications. high first-pass yield with 7-10 day prototyping from our ISO-certified facilities across China and the Philippines.

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Complex multi-branch custom cable assembly with overmolded connectors

What is Custom Cable Assembly?

Complex, High-Value Cable Assemblies Built to Your Spec

Custom cable assembly is the specialized manufacturing process of creating cable harnesses and wire assemblies tailored to your exact specifications. Unlike standard off-the-shelf cables, custom cable assemblies are engineered for specific applications requiring unique configurations of conductors, connectors, shielding, and protective coverings.

What we do NOT do: we do not manufacture simple commodity cables like standard HDMI cables, USB cables, or other low-value consumer electronics cables. Our minimum complexity threshold ensures we focus on what we do best.

What we specialize in: complex, high-value custom cable assemblies with 10+ conductors for B2B industrial applications. We excel at challenging projects requiring precision engineering, custom overmolding, EMI/RFI shielding, and demanding quality standards — see our full range of manufacturing capabilities or explore application-specific programs across our served industries.

Construction Types

Types of Custom Cable Assemblies We Manufacture

Specialized cable assembly solutions engineered for complex industrial and commercial applications.

Multi-Conductor Cable Assemblies

Complex assemblies with up to 240+ conductors for industrial control systems and automation equipment.

Up to 240+ conductors
Custom routing
Color-coded wiring

Overmolded Cable Assemblies

Ruggedized assemblies with overmolded connectors for water/dust protection in harsh environments.

IP67/IP68 rated
Strain relief
Custom molding

Shielded & Armored Cables

EMI/RFI shielded cable assemblies for industrial and medical applications requiring noise immunity.

EMI/RFI protection
Braided shielding
Armored protection

High-Flex Cable Assemblies

Flexible cable assemblies designed for continuous motion in robotic and automation applications.

10M+ flex cycles
Torsion resistant
High-cycle rated

Specialized Services & Cable Types

Explore Our Full Cable Assembly Catalog

Expert solutions for specific connector families, cable constructions, industries, and specialized manufacturing services. Every program includes drawing/BOM review, controlled crimping, and 100% electrical testing.

Sealed Splice Wire Harness

Sealed splice wire harnesses with branch-join review, adhesive heat shrink, connector alternate planning, and 100% electrical test release.

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Wire Cutting and Crimping Service

Cut, strip, crimp, connector-load, label, and electrically test harness builds with terminal-fit review, tooling cost separation, and release records.

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Wire Harness Kitting Service

Tested harness sets packed by machine, panel, vehicle, or service kit with labels, connector accessories, revision control, and release records.

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Wire Harness Tooling Service

Fixture boards, custom molds, overmold tools, crimp tooling, and test nests quoted separately from unit price for repeatable harness production.

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Bulkhead Cable Assembly

Panel feedthrough and pass-through wire harness assemblies with connector envelope review, custom mold planning, seal control, and 100% electrical test planning.

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Terminal Block Cable Assembly

Panel-ready terminal block harnesses with ferrule crimping, wire labels, DIN rail landing review, kitting options, and 100% electrical test planning.

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Low-Volume Wire Harness Manufacturing

Small-batch and pilot harness builds for 1 to 40 piece releases with BOM review, custom wire sourcing, 100% electrical testing, and release records.

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Wire Harness Rework Service

Controlled batch rescue for connector replacement, depinning, color deviations, label corrections, and 100% retest before release.

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Pressure Sensor Cable Assembly

Pressure sensor cable assemblies for robotics, pump skids, HVAC, and industrial automation with UL material review, pinout control, cost breakdowns, and 100% electrical testing.

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Molex Cable Assembly

Custom Molex cable assemblies with genuine connectors. Micro-Fit, Mini-Fit Jr, Pico-Blade series.

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JST Cable Assembly

Custom JST cable assemblies for PH, XH, SH, GH, and VH series with crimp-tooling review, low-volume samples, and production-ready documentation.

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TE Connectivity Cable Assembly

Custom cable assemblies using genuine TE Connectivity families including AMPSEAL, Superseal, Dynamic Series, and MATE-N-LOK. BOM review, connector cross-reference, and certified crimping support.

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Amphenol Cable Assembly

RFQ-ready Amphenol cable assemblies with connector-kit sourcing review, BOM control, MOQ planning, sample timing, and IPC-A-620 / UL-758 / IATF 16949 release evidence.

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Samtec Cable Assembly

Fine-pitch Samtec cable assemblies for machine-vision and industrial measurement OEMs with NDA-safe drawing review, connector sourcing checks, sample lead-time planning, and test evidence.

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High-Volume Wire Harness Manufacturing

Volume harness RFQ support with tooling cost separation, 3D file review, MOQ planning, weekly release strategy, and production evidence package.

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Anderson Power Connector Cable Assembly

High-current Anderson Powerpole, SB, SBS, and compatible DC power cable assemblies with connector sourcing review, crimp control, polarity checks, and RFQ-stage risk feedback.

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Connector Sourcing Cable Assembly

RFQ-stage connector sourcing support for constrained parts, approved alternates, MOQ planning, sample timing, and IPC-A-620 / UL-758 / IATF 16949 release evidence.

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Sumitomo Connector Cable Assembly

Custom Sumitomo connector cable assemblies with housing, terminal, seal, crimp tooling, alternate sourcing, and 100% electrical test review for automotive and robotics programs.

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Bulgin Connector Cable Assembly

Industrial Bulgin connector looms and panel cable assemblies with connector-kit review, shortage-risk planning, split-delivery options, and 100% electrical testing.

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Heavy Equipment Wire Harness

Rugged machinery harnesses for engine, power, lighting, sensor, and operator-control programs, with drawing/BOM review, China + Philippines factory options, and IPC-A-620 / UL-758 / IATF 16949 release evidence.

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Tractor Wire Harness

Stage V tractor engine and cabin harness manufacturing with NDA drawing intake, sealed routing review, CAN/ISOBUS wiring discipline, and 100% test planning.

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Push Button Cable Assembly

Control-panel push button harnesses for E-stop stations, HMI boxes, robotics cells, and machinery operators, with pinout review, labels, free prototype option, and 100% electrical test.

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Motor Cable Assembly

Servo motor power, encoder feedback, brake, VFD, and motion-control cable assemblies with connector sourcing review, shielding checks, and 100% electrical testing.

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M23 Connector Cable Assembly

M23 circular connector cable assemblies for servo power, encoder feedback, brake, and industrial motion-control programs with sourcing, shielding, strain-relief, and 100% test review.

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IO-Link Cable Assembly

Custom IO-Link sensor, actuator, master, and distribution-box cable assemblies with M8/M12 pinout review, shielding control, labels, and 100% test release.

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RJ45 Ethernet Cable Assembly

Custom RJ45 Ethernet cable assemblies for OEM devices, cabinets, smart hardware, PoE equipment, and industrial network harnesses with T568A/T568B review and wire-map testing.

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CAN Bus Cable Assembly

120 ohm CAN bus, J1939, CANopen, and NMEA 2000-style twisted-pair cable assemblies with polarity, shield, connector, and test-plan review.

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Shielded Cable Assembly

EMI-controlled cable assemblies with foil, braid, drain wire, shell grounding, strain-relief, and shield-continuity test planning for noise-sensitive equipment.

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LiDAR Cable Assembly

LiDAR, USB camera, MIPI camera, micro coax, and robotics sensor cable assemblies with route review, shielding control, design-iteration support, and 100% electrical test planning.

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LVDS Cable Assembly

High-speed LVDS display and imaging cable assemblies with 100 ohm pair review, fine-pitch connector sourcing, impedance-risk checks, and release evidence.

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Industrial Robot Harness

Robotic arm, EOAT, servo, encoder, sensor, and drag-chain harness manufacturing with moving-route review, shielding checks, revision control, and 100% electrical testing.

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Warehouse Robotics Wire Harness

AMR and fulfillment robot harnesses for wrist and elbow camera USB cables, grapple actuator wiring, force-feedback sensors, and dress-pack-ready cabling for robotics OEMs.

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Drone Cable Harness

Lightweight UAV wire harness assemblies for flight controllers, batteries, ESC branches, payload sensors, cameras, GNSS, and telemetry wiring.

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Commercial EV Truck Wire Harness

Class 4-7 commercial EV truck harnesses — HV drive, range-extender modules, LV vehicle package, signal coil, and pack-level BMS wiring. IATF 16949 process discipline, pilot-to-volume scaling.

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Construction Attachment Wire Harness

Hydraulic auger, drill, hammer, and planetary-drive attachment harnesses. Sealed Deutsch DT/DTM/DTHD constructions, IP67/IP69 ratings, 200-unit batch cadence with multi-revision sample iteration.

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Switchgear Cable Assembly

MV/LV switchgear and panelboard cable assemblies — multi-core penetration harness, MIL-DTL-5015/3108A aviation connector cable, PPAP-qualified nationalized parts, arc-flash-aware build discipline.

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Currency Equipment Cable Harness

Banknote-printing, currency-sorting, and ATM cable assemblies — board cables, stacker / reject-tray / controller harnesses, HDMI/USB breakouts. Per-drawing revision fidelity, central-bank-grade supply continuity.

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VOD Probe Cable

Sacrificial coaxial Velocity-of-Detonation probe cables for blast monitoring, mining, quarrying, and explosives R&D. 5 variants — standard, long-range, high-temperature, Kevlar-reinforced, lab precision.

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Wire Harness Tape-Wrapping Service

Production-grade tape-wrapping service for wire harnesses — fleece, vinyl, cloth, and PET tape applications with branch-routing control, wrap-coverage targets, and release documentation.

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Wire Harness Labeling Service

Custom harness labels, wire numbers, barcode tags, heat-shrink markers, revision control, and final label inspection for quote-ready OEM cable assemblies.

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Industrial Panel Wire Harness

Control panel and electrical cabinet harnesses with terminal-block fan-out, ferrule terminations, and DIN-rail panel-build discipline for industrial automation programs.

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Box Build Cable Assembly

Harness-in-enclosure integration for control boxes and instrument modules, with connector mounting, labels, 100% electrical test, and shipment-ready packout.

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M8 Sensor Cable Assembly

M8 A/B/D-code sensor and actuator cable assemblies for compact IP67 sensor wiring on industrial automation, packaging, and IoT installations.

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3.5mm Audio Cable Assembly

Custom TRS and TRRS audio cable assemblies with pinout review, shielding choices, strain relief, overmold options, labels, and 100% electrical testing.

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Deutsch Connector Cable Assembly

Sealed Deutsch DT, DTM, DTP, HDP20, and HD30 cable assemblies with connector-kit review, crimp control, sealing checks, and 100% electrical testing.

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Medical Connector Manufacturers

Compare medical connector manufacturers and cable-assembly partners for patient monitoring, imaging, therapy, and laboratory devices with connector-family review, traceability, and validation inputs.

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Waterproof Wire Harness

IP67/IP68 waterproof wire harness manufacturing. Submersion tested, salt spray certified.

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Custom Medical Cable Assembly

Medical device cable assembly manufacturing for patient monitoring, imaging, therapy, and laboratory equipment with traceability, material review, and 100% electrical testing support.

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OEM Cable Assembly

OEM cable assembly manufacturing for branded equipment makers. Controlled BOM, revision management, private label packaging, and scalable contract production.

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Cable Assemblies Manufacturers

Commercial cable assembly manufacturing for OEM buyers who need drawing review, BOM control, prototypes, 100% electrical testing, and repeatable production releases.

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Wiring Harness Manufacturers Australia

Commercial wire harness supply for Australian OEMs, specialty vehicle builders, mining systems, and industrial integrators. Drawing review, BOM control, sample timing, and export-ready delivery.

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Prototype Wire Harness Services

Rapid prototype wire harness manufacturing. 7-10 day turnaround. 1-50 units.

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Overmolded Cable Assembly

Custom injection-molded thermoplastic encapsulation. IP67/IP68 sealed, strain-relief integrated.

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Strain Relief Cable Assembly

Connector-exit strain relief with boot, gland, heat shrink, sleeve, clamp, or overmold review for cable assemblies that see pull, bend, vibration, or service handling.

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Battery Cable Assembly

High-current battery cables for EV, energy storage, and industrial power. Up to 1000V DC, IATF 16949 certified.

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8SQMM Cable Assembly

Custom 8 mm2 power cable assemblies for DC power, battery, UPS, solar, and industrial equipment programs with terminal-fit review, crimp evidence, and 100% electrical testing.

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Electric Motorcycle Wire Harness

Electric motorcycle wire harness manufacturing for traction battery, BMS, controller, dashboard, charge-port, and lighting harness programs with prototype-to-production support.

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High Voltage Cable Assembly

Custom high voltage cable assemblies for EV platforms, energy storage, charging equipment, and industrial power systems. Shielded, orange-jacketed, and 100% tested.

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High-Temperature Cable Assembly

Heat-resistant PTFE, silicone, probe, sensor, and test-measurement cable assemblies with material review, tolerance control, and release test planning.

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EV HVAC Adapter Cable Assembly

RFQ-ready EV HVAC adapter cable assemblies for thermal-management harness programs with BOM review, alternate-material quoting, connector-risk checks, and IPC-A-620 / UL-758 / IATF 16949 evidence.

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TC-ER Certified Power Cable

Tray cable exposed-run power assemblies for industrial equipment with TC-ER marking review, controlled terminations, route labels, and 100% electrical testing.

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Coaxial Cable Assembly

Custom RF coaxial cable assemblies from DC to 110 GHz. SMA, BNC, N-Type connectors. 100% VSWR tested.

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SMA Connector Cable Assembly

Custom SMA and RP-SMA coaxial cable assemblies for RF, antenna, wireless, test, and industrial equipment programs with connector sourcing review, impedance control, and RF test planning.

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Rosenberger Connector Cable Assembly

Custom Rosenberger FAKRA, HSD, HFM, RF coax, and automotive data cable assemblies with connector sourcing review, impedance control, and RF/data test planning.

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Optical Cable Assembly

Custom fiber optic cable assemblies for singlemode, multimode, MPO, LC, and ruggedized builds with polarity control and insertion-loss testing.

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Ribbon Cable Assembly

Custom flat ribbon cable assemblies with IDC, D-Sub, and ZIF connectors. 4-80 conductors, 0.5-2.54 mm pitch. 100% tested.

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FPC Cable Manufacturers

Custom FPC and FFC cable manufacturing for displays, compact medical devices, industrial HMI modules, and other fine-pitch interconnect programs.

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USB Cable Assembly

Custom USB cable assemblies for USB 2.0, USB 3.x, and USB-C programs. Panel-mount, overmolded, charging, and data-capable builds with 100% electrical testing.

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FAKRA Cable Assembly

Custom automotive FAKRA cable assemblies for ADAS, telematics, GNSS, and infotainment programs with coding review, impedance control, and production-ready test planning.

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Automotive Wire Harness Clips

Clip-ready automotive wire harness builds for EV, truck, and specialty vehicle programs with retention review, branch routing control, and production-ready documentation.

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Cable Loom Assembly

Custom cable loom manufacturing with routing review, conduit or sleeve protection, label maps, controlled crimping, and 100% electrical testing.

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Custom Braided Cable Assembly

Braided mining and industrial cable assemblies with exact core colors, stripe patterns, laser markings, molded connector exits, and 100% electrical testing.

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Marine Audio Cable Assembly

Boat OEM audio cable assemblies with RFQ review, 3-4 week tooling planning, free sample support, weekly delivery strategy, and IPC-A-620 / UL-758 release controls.

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Pigtail Wire Connectors

Custom pre-terminated pigtail connectors with factory-crimped leads. 28-10 AWG, automotive & industrial grades. 100% pull-force tested.

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M12 Cable Assembly

Custom M12 cable assemblies with A/B/C/D/X/L-coded connectors. IP67 overmolded, PUR/PVC jacket, 100% tested for industrial automation and IIoT.

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Micro Coaxial Cable Assembly

Fine-pitch micro coaxial cable assemblies for compact cameras, medical imaging, wireless modules, and miniature RF interconnects.

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Factory Wiring Harness

Volume production wire harness manufacturing with automated crimping, fixture-board assembly, IPC/WHMA-A-620 workmanship, and 100% electrical test. 50 to...

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Wire Harness Testing Service

Continuity, polarity, hipot, insulation resistance, pull-force checks, and documented test records for production-ready cable assemblies.

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Wire Harness Tester

Fixture-planned tester support for OEM wire harness programs that need continuity, polarity, hipot, and report logic defined before production release.

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ICT Testing Service

Netlist-based electrical verification with continuity, resistance windows, hipot options, fixture planning, and traceable release records.

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By Industry

Custom Cable Assembly Solutions by Industry

Industry-certified cable assembly manufacturing for demanding applications.

Automotive Cable Assembly

IATF 16949 certified cable assemblies for EV powertrains, ADAS systems, and vehicle control units.

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Medical Cable Assembly

ISO 13485 supply chain compliant assemblies for diagnostic equipment and surgical instruments.

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Industrial Cable Assembly

Heavy-duty cable assemblies for PLCs, control panels, and manufacturing equipment.

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Robotics Cable Assembly

High-flex assemblies for industrial robots, AGVs, and collaborative robotic systems.

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FAQ

Custom Cable Assembly FAQs

Common questions about our cable assembly services, MOQ, lead times, sourcing, and certifications.

What is custom cable assembly?

Custom cable assembly is the process of designing and manufacturing cable assemblies tailored to your exact specifications, including custom wire gauges, conductor counts, connector types, shielding, and lengths. Unlike off-the-shelf cables, custom assemblies are engineered for your specific application requirements.

What is your minimum order quantity (MOQ)?

For prototypes and samples, we accept orders from 1-10 pieces. For production runs, our standard MOQ is 500+ units, but this is negotiable based on complexity and project requirements.

Do you provide design services?

No, we focus exclusively on manufacturing excellence. We do not offer design services, which allows us to keep costs lower and pass savings to our customers. However, we provide comprehensive DFM (Design for Manufacturing) feedback to optimize your existing designs for production.

What types of cable assemblies do you NOT manufacture?

We do not manufacture simple commodity cables like standard HDMI cables, USB cables, or other low-value consumer electronics cables. We specialize in complex, high-value custom cable assemblies with 10+ conductors for B2B industrial applications.

Where are your manufacturing facilities located?

We have 2 manufacturing facilities: China (main facility) and Philippines (medical devices). Our team provides global sales and technical support for customers worldwide.

What is your typical lead time?

Samples and prototypes: 7-10 business days. Production runs: 2-4 weeks depending on complexity and quantity. Rush orders available for additional fees.

Do you source connectors globally?

Yes! We have established partnerships with major connector suppliers worldwide (Molex, TE Connectivity, Amphenol, JAE, Hirose). Our global sourcing network allows us to offer better pricing and faster lead times than single-source competitors.

What certifications do you have?

We are ISO 9001:2015 certified for quality management and IATF 16949 certified for automotive manufacturing. Our supply chain is ISO 13485 ready for medical device applications. All products are RoHS and REACH compliant.

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