Engineering-driven cable assembly solutions built to your exact specifications. Whether you need 10 prototypes or 100,000 production units, PCB Insider delivers precision, quality, and on-time delivery for the world's most demanding industries.
In today's competitive manufacturing landscape, the reliability of your cable assemblies directly impacts product performance, warranty costs, and brand reputation. A single defective cable in an automotive control unit, a medical monitoring device, or an aerospace navigation system can have serious consequences — from costly field recalls to safety hazards.
That's why over 500 companies across 35 countries trust PCB Insider as their custom cable assembly partner. Our vertically integrated manufacturing facility combines automated precision with skilled craftsmanship, ensuring every cable assembly meets or exceeds IPC/WHMA-A-620 Class 3 workmanship standards — the highest quality classification in the cable and harness industry.
Unlike contract manufacturers that treat cable assembly as an afterthought, cable interconnects are our core competency. Our dedicated engineering team specializes in cable and wire harness manufacturing, bringing deep domain expertise to every project from initial DFM review through production ramp. We don't just build to your drawings — we optimize your designs for manufacturability, cost, and long-term reliability.
From simple two-wire assemblies to complex multi-conductor shielded cables, our capabilities cover the full spectrum of cable interconnect solutions.
Complex multi-conductor cable assemblies with up to 200+ wires, precision-stripped, terminated, and tested for automotive, medical, and industrial control applications.
Extensive connector library including Molex, JST, TE Connectivity, Amphenol, Deutsch, and more. We source and integrate the exact connectors your design demands.
Cable assemblies rated for extreme temperatures (-40°C to +200°C), chemical exposure, UV resistance, and continuous flexing applications in demanding environments.
Custom overmolded strain relief, IP67/IP68 sealed connectors, and potted assemblies providing maximum protection against moisture, vibration, and mechanical stress.
Braided shields, foil wraps, and combination shielding solutions for signal-sensitive cable assemblies used in telecommunications, medical imaging, and avionics.
Power distribution cables rated up to 600V with proper insulation, color-coding, and safety testing compliant with UL, CSA, and CE requirements.
Seamless transition from single-unit prototypes to 100,000+ unit production runs. Dedicated NPI team ensures design-for-manufacturing optimization at every stage.
Complete value-add services including labeling, bundling, heat-shrink application, lacing, braiding, coiling, and custom packaging per your specifications.
Every cable assembly undergoes continuity, hi-pot, and insulation resistance testing. Automated test equipment ensures zero-defect deliveries to your production line.
| Parameter | Specification |
|---|---|
| Wire Gauge Range | AWG 30 – AWG 4/0 |
| Conductor Count | 1 – 200+ conductors |
| Assembly Length | 50mm – 30m+ |
| Operating Temperature | -40°C to +200°C |
| Voltage Rating | Up to 600V |
| Shielding Options | Braid, foil, spiral, combination |
| IP Rating | Up to IP68 |
| Connector Brands | Molex, JST, TE, Amphenol, Deutsch, JAE, Hirose |
| Insulation Materials | PVC, PTFE, silicone, TPE, PE |
| Quality Standard | IPC/WHMA-A-620 Class 2 & 3 |
| Prototype Lead Time | 3–5 business days |
| Production Lead Time | 2–4 weeks (volume dependent) |
A proven 6-step process refined over years of manufacturing thousands of unique cable assembly designs for clients worldwide.
Submit your drawings, specifications, or even a rough concept. Our engineering team performs a thorough Design for Manufacturing analysis, identifies potential issues, and recommends optimizations that reduce cost without compromising performance.
We produce first article samples within 3–5 business days. Each prototype undergoes the same rigorous testing as production units, ensuring you validate the exact assembly that will ship in volume.
Receive detailed First Article Inspection reports with dimensional measurements, electrical test data, and material certifications. Your approval triggers the transition to production tooling and fixture setup.
Automated cutting, stripping, crimping, and soldering stations ensure precision and consistency. In-process quality checks at every station, combined with 100% end-of-line electrical testing, guarantee zero-defect output.
Visual inspection per IPC/WHMA-A-620 workmanship standards. Custom labeling, serialization, and packaging per your requirements. Full traceability documentation accompanies every shipment.
Flexible shipping via air, sea, or express courier with real-time tracking. VMI (Vendor Managed Inventory) and Kanban programs available for high-volume customers requiring just-in-time delivery.
Our custom cable assemblies serve critical applications across the world's most demanding industries.
Battery management cables, sensor harnesses, infotainment connections, ADAS wiring, and EV charging cables meeting IATF 16949 and automotive OEM specifications.
Patient monitoring cables, surgical instrument assemblies, imaging equipment interconnects, and diagnostic device wiring compliant with ISO 13485 and biocompatibility requirements.
Avionics cable assemblies, mil-spec wiring harnesses, UAV power distribution, and satellite communication cables meeting AS9100 and MIL-DTL standards.
Robotic arm cables, PLC wiring assemblies, sensor and actuator connections, and drag-chain compatible cables for CNC, packaging, and material handling equipment.
Fiber optic assemblies, RF/coaxial cables, data center interconnects, and network infrastructure wiring for 5G base stations and enterprise networking equipment.
Solar panel wiring harnesses, wind turbine cable assemblies, battery storage interconnects, and inverter cables designed for outdoor exposure and 25+ year service life.
“Every cable assembly we produce carries our reputation. We invest in automated manufacturing equipment and rigorous testing protocols not because regulations require it, but because our customers' products depend on it. When a cable assembly leaves our facility, it must perform flawlessly — in a patient's hospital room, inside an aircraft engine bay, or on a factory floor running 24/7.”
All cable assemblies manufactured to IPC/WHMA-A-620 workmanship standards. Class 3 capability for high-reliability applications in aerospace, defense, and medical devices.
Certified quality management system governing every aspect of our manufacturing process — from incoming material inspection to final shipment verification.
Automated continuity, hi-pot (dielectric withstand), and insulation resistance testing on every single cable assembly. No exceptions, no sampling — 100% tested.
Complete material and process traceability from raw material lot numbers through finished goods. Batch records, test data, and certificates of conformance accompany every order.
Statistical Process Control monitoring on all critical crimp dimensions, solder joints, and assembly parameters. Real-time data collection ensures process stability across production runs.
UL and CSA recognized facility for safety-critical cable assemblies. Component-level UL recognition ensures your cable assemblies meet North American safety requirements.
We have no hard minimum order quantity. We regularly produce prototype runs of 1–10 units as well as production orders of 100,000+ units. Our flexible manufacturing setup allows us to be cost-effective at any volume. For orders under 100 units, a small setup fee may apply to cover tooling and fixture preparation.
Standard prototype lead time is 3–5 business days after design approval. For urgent requirements, we offer an expedited 24–48 hour express prototype service. This fast turnaround allows you to validate your design early and avoid costly delays later in the product development cycle.
Our facility is ISO 9001:2015 certified for quality management systems. We manufacture all cable assemblies to IPC/WHMA-A-620 Class 2 and Class 3 workmanship standards. For automotive customers, we maintain IATF 16949 compliance. We also hold UL and CSA certifications for safety-critical assemblies.
We offer both turnkey and consigned manufacturing models. In turnkey mode, we source all connectors, cables, terminals, and components from authorized distributors — leveraging our volume purchasing power for competitive pricing. You can also supply specific components if you have preferred vendors or existing inventory.
Every cable assembly undergoes 100% electrical testing including continuity verification, hi-pot (dielectric withstand) testing, and insulation resistance measurement. For high-reliability applications, we also offer environmental stress screening, pull-force testing on crimped connections, and X-ray inspection of solder joints.
We use automated manufacturing equipment (CNC wire cutting, pneumatic crimping, robotic soldering) with real-time process monitoring. SPC (Statistical Process Control) tracks critical dimensions throughout every production run. Combined with in-process quality gates and 100% end-of-line testing, this system maintains defect rates below 50 PPM.
Complex multi-branch wire harnesses with custom routing, breakouts, and full continuity testing.
Learn MoreFull SMT and through-hole PCB assembly with automated inspection and functional testing.
Learn MoreComplete electromechanical assembly including enclosure, wiring, and end-of-line system testing.
Learn MoreUpload your drawings, BOM, or specifications and receive a detailed engineering review and competitive quote within 24 hours. Our team is ready to turn your cable assembly requirements into production reality.
Free shipping on prototype orders | No minimum order quantity