Cable Assembly Manufacturing Services

Provide a dimensional drawing (PDF or CAD), a bill of materials specifying connector part numbers, and electrical requirements (voltage, current, shielding type). For complex assemblies, a 3D STEP file helps us quote faster. We can also work from physical samples or reverse-engineer existing assemblies — our engineering team will generate production drawings within 3 business days.

Prototype orders start at 10 pieces with a 1–2 week lead time. Production MOQ is 200 pieces, with volume pricing breaks at 1,000 and 5,000 units. For standard connector types (M12, D-Sub, RJ45), we can often reduce MOQs to 50 pieces using stocked components from our warehouse.

All assemblies are manufactured to IPC/WHMA-A-620 Class 2 or Class 3 requirements. Our facility holds ISO 9001:2015 and IATF 16949 certifications. For automotive applications, we comply with LV 112 specifications; for medical devices, assemblies meet IEC 60601-1 requirements. UL-listed cables and connectors are used wherever specified.

Choose cable assembly when your application needs pre-terminated connectors on continuous shielded or multi-conductor cables — typically for signal transmission, data communication, or sensor connections. Wire harnesses are better for power distribution with multiple branch points and bare terminals. If your design has more than 3 connector interfaces on a single cable run, cable assembly is usually the more reliable and cost-effective choice because each connector is factory-terminated and tested as a unit.

Standard hipot testing is performed at 1500V DC for 300V-rated cables and 3000V DC for 600V-rated cables, per IEC 60950-1 requirements. For high-voltage assemblies rated 1kV+, we test up to 5000V DC. Test duration is 60 seconds for first-article qualification and 1 second for production screening, with leakage current thresholds set per your specification or IPC/WHMA-A-620 defaults.

We offer three shielding approaches: aluminum foil with drain wire (90%+ coverage for EMI above 10MHz), tinned copper braid (85–95% coverage for RFI below 10MHz), and combination foil-plus-braid (98%+ coverage for demanding environments). Shield termination methods include 360° crimp ferrules, solder-back sleeves, and pigtail connections — selected based on your frequency range and insertion loss requirements per IEC 62153-4-3.

Prototype quantities (10–50 pcs): 1–2 weeks. Pilot run (50–500 pcs): 2–3 weeks. Production volumes (500+ pcs): 3–4 weeks for first article, then 2–3 weeks for repeat orders. Tooling for custom overmolded connectors adds 3–4 weeks to the initial lead time. We maintain buffer stock on repeat orders to support JIT delivery schedules.