Prototype Cable Assembly ServicesProduction-Quality Samples in 7-10 Days
Validate your custom cable assembly design with professional prototypes before committing to full production. Complex assemblies only—10+ conductors, specialized connectors, IATF 16949 certified facilities.
⚡ 4-Hour Engineering Response • Global Technical Support
What is Prototype Cable Assembly?
Prototype cable assembly is a specialized manufacturing service that produces small quantities (1-50 units) of custom cable assemblies for design validation, functional testing, and certification—before committing to full-scale production.
What You Get
- Production-quality samples (1-50 units) manufactured to your exact specifications
- Functional testing for mechanical fit, electrical performance, and connector compatibility
- Design validation before investing $5,000-$50,000 in production tooling
- FREE Design for Manufacturing (DFM) analysis and recommendations
Why It Matters
- Catch design errors early—fixing issues costs 10-50x more after tooling
- Accelerate time-to-market by 4-8 weeks with parallel testing
- Present functional samples to clients, investors, or certification agencies
- Test alternative components and specifications without production risk
Our Specialization
We focus exclusively on complex, high-value cable assemblies. Our expertise lies in assemblies with 10-240 conductors, multiple connector types, custom routing, EMI/RFI shielding, and specialized materials. We do NOT manufacture simple commodity cables like HDMI or USB—our equipment and processes are optimized for assemblies where precision, quality, and engineering expertise matter.
Why Choose Professional Cable Assembly Prototyping?
Investing in professional prototyping de-risks your product development, accelerates time-to-market, and saves significant costs compared to jumping straight to full-scale production.
Risk Mitigation Through Early Testing
Identify design flaws, compatibility issues, and manufacturing challenges before committing to full production. Early validation prevents costly errors and reduces project risk.
Faster Time-to-Market
Validate your design in just 7-10 days, accelerating product development by weeks. Fast turnaround prototyping lets you test, iterate, and improve quickly.
Complete Design Verification
Test fit, form, function, and performance in real-world conditions before investing in production tooling. Ensure your design works exactly as intended.
Cost Optimization
Catch errors early and refine your design for manufacturability, saving 20-40% on production costs. Design improvements at the prototype stage pay for themselves many times over.
Innovation Testing
Experiment with new connector types, wire configurations, and assembly methods without production-scale risk. Test multiple design variations quickly and cost-effectively.
Stakeholder Validation
Present functional samples to clients, investors, or certification bodies for approval before mass production. Physical prototypes accelerate decision-making and approvals.
Our Prototyping Capabilities
IATF 16949 certified facilities equipped to manufacture complex custom cable assemblies across a wide range of specifications and industries.
Complex Multi-Conductor Assemblies
- 10-240+ conductors per assembly
- 28-10 AWG wire gauge range
- Custom color coding and routing schemes
- Braided, twisted pair, or parallel configurations
Custom Connector Integration
- Molex, TE, Amphenol, JAE, Hirose connector families
- Overmolding and strain relief options
- IP67/IP68 environmental sealing
- Military-spec and industrial connectors
Shielding & Protection
- EMI/RFI shielding (braided, foil, spiral)
- Cable armor and conduit protection
- Heat shrink tubing and protective sleeving
- Chemical and abrasion resistant jacketing
Technical Specifications
- Length: 50mm to 50+ meters
- Voltage rating: up to 1000V
- Current capacity: up to 100A per conductor
- Temperature range: -40°C to +200°C
Fast-Track Your Development with Rapid Prototyping
Industry-leading 7-10 day turnaround from order to delivery. No minimum order quantities. Production-quality manufacturing processes.
7-10 Day Turnaround
Industry-leading speed from order confirmation to shipped samples. Rush service available for 2-3 day turnaround when you need samples urgently.
Flexible Quantities
Order from 1 to 50 units without minimum order requirements or production-scale tooling costs. Pay only for what you need to test.
Design Iteration Support
FREE engineering feedback and Design for Manufacturing (DFM) analysis worth $500 with every order. Get expert recommendations to optimize your design.
Production-Ready Process
Samples manufactured using the same equipment, processes, and quality standards as full production runs. What you test is what you get in production.
Typical Prototype Timeline Breakdown
Global Component Sourcing for Better Value
Our worldwide connector procurement network delivers authentic components at 15-30% lower cost with 3-7 days faster lead times than single-source competitors.
Worldwide Supplier Network
Direct partnerships with Molex, TE Connectivity, Amphenol, JAE Electronics, Hirose, Phoenix Contact, and 100+ authorized distributors across North America, Europe, and Asia.
Cost Savings of 15-30%
Volume purchasing agreements and multi-region sourcing reduce your component costs compared to single-source competitors. We pass these savings directly to you.
Faster Lead Times
Global inventory access and strategic stockpiling of common connectors cut 3-7 days from typical procurement cycles, accelerating your project timeline.
Authentic Component Guarantee
All connectors sourced from authorized distributors with full traceability, certifications (UL, CE, RoHS), and counterfeit protection measures.
Authorized Distributor Partnerships
+ 100+ other authorized connector suppliers across North America, Europe, and Asia
Comprehensive Testing & Quality Assurance
Every sample undergoes rigorous electrical, mechanical, signal integrity, and environmental testing to ensure your design performs as specified.
Electrical Testing
- Continuity and resistance testing (100% inspection)
- Insulation resistance: >100MΩ at 500VDC
- High-potential (Hi-Pot) testing: 1000V-3000V
- Contact resistance: <5mΩ per connection
Mechanical Testing
- Connector insertion/extraction force testing
- Cable flex life testing: 10,000-1,000,000+ cycles
- Vibration resistance per ASTM D999
- Pull strength and tensile testing
Signal Integrity Testing
- Impedance verification (±5Ω tolerance)
- Crosstalk and EMI susceptibility testing
- Signal attenuation and loss measurement
- High-frequency performance validation up to 10GHz
Environmental Testing
- Temperature cycling: -40°C to +200°C
- Humidity resistance: 85% RH at 85°C
- Salt spray corrosion (per ASTM B117)
- IP67/IP68 water immersion testing
Every prototype tested before shipment. Test reports and certificates included.
Industries We Serve
Professional prototyping services for high-reliability applications in automotive, medical, industrial, and robotics sectors.
Automotive & EV
IATF 16949 certified prototypes for electric vehicle powertrains, ADAS sensors, battery management systems, and in-cabin control modules.
Medical Devices
ISO 13485 supply chain compliant samples for diagnostic imaging, surgical robotics, patient monitoring systems, and implantable device interconnects.
Industrial Automation
Rugged prototypes for PLCs, servo motors, industrial robots, CNC machines, and factory automation equipment.
Robotics & AGV
High-flex assemblies for collaborative robots (cobots), automated guided vehicles, warehouse automation, and mobile robotics platforms.
Our Transparent Prototyping Process
From initial consultation to delivered prototypes in 7-10 days. Clear communication, comprehensive documentation, and production-quality results at every step.
Technical Consultation & Requirements Analysis
Submit your specifications (CAD drawings, schematics, BOM, connector datasheets). Our global engineering team reviews your requirements and responds within 4 hours with initial feasibility assessment.
- Feasibility confirmation
- Technical questions clarification
- Alternative component recommendations
Quotation & Design for Manufacturing (DFM) Review
Receive detailed pricing breakdown including materials, labor, tooling (if required), and shipping. FREE DFM analysis identifies potential manufacturing issues and suggests optimizations for cost and reliability.
- Itemized quotation
- DFM analysis report ($500 value)
- Lead time confirmation
Global Component Sourcing & Procurement
We source connectors, terminals, wire, and accessories from our worldwide supplier network, ensuring authentic components at competitive pricing with full traceability documentation.
- Component certificates of conformance
- Material traceability records
- RoHS/REACH compliance documents
Prototype Assembly & First Article Inspection
Skilled technicians assemble your prototype wire harness using production-grade equipment. First article undergoes 100% electrical testing and dimensional verification against your specifications.
- Assembled prototype units
- First article inspection report
- High-resolution product photos
Quality Testing & Documentation
Comprehensive electrical, mechanical, and environmental testing per your requirements or industry standards. Full test reports and certificates of conformance provided with every prototype shipment.
- Electrical test reports
- Mechanical test data
- Certificate of conformance
- Material certificates
Secure Packaging & Express Shipping
Anti-static packaging with protective foam inserts ensures your prototypes arrive in perfect condition. DHL/FedEx express shipping with tracking worldwide and worldwide.
- Secure packaging
- Express courier shipping
- Tracking information
- Customs documentation
Global Technical Support & Sales
Our our office provides local timezone support, English-speaking technical consultation, and global business hours availability—eliminating language barriers and 12-hour time zone delays common with overseas-only suppliers.
Local Support Team
English-speaking engineers available during AEST/AEDT business hours for technical questions, quote clarifications, and project consultations.
Global Manufacturing
3 IATF 16949 certified facilities in China, Thailand, and Philippines provide supply chain redundancy and geographic risk mitigation.
4-Hour Response Time
Submit your prototype inquiry before 2 PM AEST and receive initial technical review and feasibility assessment the same business day.
Sales, technical support, and customer service for customers worldwide.Note: Manufacturing is performed at our China, Thailand, and Philippines facilities—our office does not have production capabilities.
Why Partner with Us for Complex Wire Harness Prototypes?
We're not a commodity cable factory—we're your specialized partner for high-value, complex prototype wire harness manufacturing.
Complex Assemblies Only - No Simple Cables
We don't waste resources on commodity HDMI or USB cables. Our expertise is in complex, high-value custom assemblies with 10+ conductors, custom routing, and specialized connectors.
Global Component Sourcing
Our worldwide connector procurement network (Molex, TE, Amphenol, JAE, Hirose) provides 15-30% cost savings and 3-7 days faster lead times versus single-source competitors.
Production-Quality Samples
We manufacture samples using the same IATF 16949 and ISO 9001 certified processes as our production runs, ensuring your prototypes accurately represent final product quality.
Global Technical Support
Our global office provides local timezone technical support, consultation in English, and worldwide business hours availability—no language barriers or delays.
Scalable from Prototype to Production
Seamless transition from prototype (1-50 units) to low-volume (500+) to mass production (10,000+) without changing suppliers, re-tooling, or re-qualifying.
Rapid 7-10 Day Delivery vs. Industry 3-4 Weeks
Our streamlined process, pre-stocked connector inventory, and dedicated production line deliver samples 60% faster than traditional manufacturers.
Request Your Prototype Wire Harness Quote
Submit your specifications and receive a detailed quotation with FREE DFM analysis within 24-48 hours. our technical team responds within 4 hours.
Transparent Prototype Pricing
Clear pricing guidelines to help you budget your prototype project. Final quotes provided within 24-48 hours based on your specific requirements.
- 10-30 conductors
- Standard connectors (Molex, TE, Amphenol)
- Basic crimping and assembly
- Length up to 2 meters
- 30-120 conductors
- Multiple connector types
- Shielding or custom routing
- Length up to 10 meters
- 120-240+ conductors
- Military-spec or custom connectors
- Overmolding or IP67/IP68 sealing
- Extreme specifications
What's Included in Every Prototype Quote
Our Limitations & What We Don't Manufacture
Transparency is key to successful partnerships. Here are applications and specifications we cannot support, so you don't waste time on an incompatible inquiry.
We Do NOT Manufacture
- Simple Commodity CablesStandard HDMI, USB, DisplayPort, Ethernet, audio cables, or any off-the-shelf consumer electronics cables
- Low-Complexity AssembliesAssemblies with fewer than 8 conductors using only standard connectors (below our complexity threshold)
- Direct-to-Consumer ProductsWe serve B2B customers only. No retail, e-commerce, or end-consumer sales
- Fiber Optic AssembliesWe specialize in electrical copper assemblies only, not fiber optic cables or hybrid fiber-copper
- Design Engineering ServicesWe provide manufacturing, not electrical design consulting or CAD drawing services
Technical Limitations
- Ultra-High Frequency (>12 GHz)Our standard processes are optimized for signals up to 10GHz. Specialty RF/microwave assemblies require different expertise
- Extreme Cryogenic (-100°C or lower)Standard materials rated -40°C to +200°C. Liquid nitrogen or extreme cryogenic applications not supported
- Nuclear/Radiation HardenedAssemblies for nuclear power or high-radiation environments require specialized materials we don't stock
- FDA Class III Medical ImplantablesOur ISO 13485 ready supply chain supports external medical devices, not surgically implantable products requiring FDA Class III certification
- Explosive/Hazardous Atmospheres (ATEX Zone 0)We can support Zone 2 applications but not Zone 0/1 requiring intrinsically safe certification
Unsure if your project fits our capabilities? Contact our our technical team with your specifications. We'll provide honest feasibility assessment within 4 hours—even if we can't help, we may recommend alternative suppliers.
Our Quality Guarantees & Policies
Clear policies that protect your investment and ensure successful prototype outcomes.
Prototype-to-Production Guarantee
Your approved prototype will be manufactured using identical materials, connectors, wire specifications, and processes when you transition to production. No component substitutions without your written approval.
- Same connector brands and part numbers
- Same wire manufacturer and specifications
- Same assembly processes and quality standards
Rework & Replacement Policy
If your prototype wire harness fails to meet agreed specifications due to our manufacturing error, we will remake it at no charge within 5 business days.
- FREE remake for our manufacturing defects
- Design change requests charged at 50% of original quote
- Express shipping included for replacement units
NDA & IP Protection
We sign mutual Non-Disclosure Agreements (NDAs) to protect your proprietary wire harness designs, connector selections, and technical specifications.
- Standard NDA template or use your company's agreement
- Segregated project files with access control
- No design reuse without written permission
Shipping & Customs Support
We handle all export documentation, customs paperwork, and compliance certificates for international imports. You pay only actual shipping costs—no hidden fees.
- Commercial invoice, packing list, certificates provided
- Import duties/GST are your responsibility (standard practice)
- DHL/FedEx with full tracking and insurance
Testing Standards We Follow
Prototypes manufactured and tested per internationally recognized standards for quality and reliability