Cable assembly is indeed an inevitable part of the printed circuit board assembly process. In this process, many wires get collected and connected during the second stage of PCB assembly. But, do you know what a cable assembly is? Are you aware of its processes, applications, and diverse classification?

If you are interested in exploring all about cable assembly, make sure to read this article till the end. 

Definition of Cable Assembly? 

Cable assembly is nothing but a group of wires or cables connected into a single unit. Cable assembly is a significant and inevitable part of PCB assembly. It is done by hand soldering, and the company must be authorized for it. So, always choose the right company only after seeing their certificate. 

Over modeling is a special capacity offered by several Electronic manufacturing services companies. It means a tiny part gets developed using various layers and components. Among them, the first one must get coated with more than one element while creating. 

Our most popular cable assembly services include

Cutting and organizing wires: Before going further, it is crucial to cut the wires first. We, as professional cable assembly manufacturers, also prioritize this method from the beginning. We cut the wires using 100% automatic devices. The machines used by us do not only cut wires but also organize them properly. The steps of cutting and organizing wires follow: 

Cutting> stripping>tin dipping> crimping (applicable for both single and multi-core wires)

Crimped cable assemblies: It is the second stage of Cable assembly manufacturing. In this process, the prepared pieces of wires get crimped. We use automated crimping devices and lots of crimping tools for all major Cable assembly manufacturers such as:

• TE connectivity 
• Molex
• Amphenol
• JST
• Hiros
• ITT cannon

Cable looms and harness assembly: Last but not least, we provide all kinds of cable assembly services, including multi-layered cable assembly, coaxial cable assembly, battery cable assembly, flat ribbon cable assembly, wire jumper cable assembly, military cable assembly, and medical cable assembly. All of these assemblies benefit different industrial, military, mariner, and small business industries. 

Featured Cable Assemblies Solutions 

• Overmolded cable assemblies 
• Medical device cable
• Military site harnesses
• Crimped cable assembly
• IDC cable assembly 

Brief overview

There are so many different types of cable assemblies popular in the world of electronic goods. Some of them are multi-layered, where some are wire jumpers. Each of them has different construction, components, and applications. We, as one of the leading Cable assembly manufacturers, provide seven major Custom cable manufacturing services. These are: 

• Multi-conductor Cable Assemblies
• Coaxial cable assemblies 
• Battery cable assemblies 
• IDC flat ribbon cable assemblies 
• Wire jumper cable assemblies 
• Military cable assemblies 
• Medical cable assemblies

All of these assemblies, their configuration, and their applications are listed down below. 

Multi-conductor Cable Assemblies

As the name suggests, a multi-layered cable assembly is a kind of Cable assembly containing a considerable number of conductors inside. Mostly, a multi-layered conducted contains two to twenty-five conductors. However, cable made for special purposes can contain more than twenty-five conductors. 

The conductors are positioned using an insulation sheath inside one single cable. This type of cable assembly is known as a multi-layered cable assembly. 

The applications of multi-conductor cable assemblies are many, including: 

• Communication system 
• Data transmission system 
• Audio system 
• High voltage current transmission 
• Remote signaling communication 

Being multi-layered, it is strong and durable. It delivers consistent power flow, high-quality data transmission and lasts longer as well.

Coaxial Cable Assemblies 

Coaxial Cable assembly, also known as RF or Rflex cable assembly, is an assembly that gets developed using various types of connectors depending on the application. The outcome of a coaxial cable assembly can be rigid, flexible, semi-rigid, etc. The connectors used to build a coaxial cable assembly are: 

• BNC
• TNC
• SMA
• MCX
• SMP
• MMBX
• MMCX
• N-type
• SMB
• UHF

This type of Cable assembly often gets used to transmit radio frequency and signals in the multi megahertz range. Some of the common applications of coaxial or RF assemblies are: 

• Military
• Aerospace 
• Transportation 
• Radiofrequency signals 
• Communicators 
• Test equipment 
• Sensors

Coaxial cable assemblies are versatile and contain high-data transfer capabilities, supporting various stations and low error rates.

Battery Cable Assemblies

A battery Cable assembly is a short run of battery cables. The two endings of a battery get terminated while making a battery cable assembly. In this way, a battery supports one or more batteries to connect to an electric system. The ends can get canceled using various boots. Generally, twelve to forty-eight inches is the most seen length of a battery cable assembly while increasing or decreasing depending on the situation.

Small industries and businesses mostly use this type of Cable assembly. Battery cable assemblies have the power of resisting moisture, vibration, and other hazardous environments. The uses of battery Cable assemblies include: 

• Medical
• Automotive
• Mariner 
• Manufacturing 
• Military 

IDC Flat Ribbon Cable Assemblies

It is a flat and rectangular-shaped Cable assembly with its name for its similarities with a shape of a flat ribbon. While making an IDC flat ribbon cable assembly, the connectors and other components get placed parallel to one another on the flat plane, making the assembly look flat and wide. 

The best benefit of a ribbon cable assembly it’s that it allows mass termination to the insulation-displacement connectors or IDC. However, it can get connected using solder-bucket connections or crimp contacts. These assemblies get used as interconnectors for internal peripherals. 

Special features of an IDC flat ribbon assembly are: 

• Any pin count to 2 to 50 per row
• Low profile 
• Slim body design 
• Single and double row
• Socket and terminal assemblies 

The applications of IDC flat ribbon cable assemblies are:

• Internal peripheral in computers 
• CD drives
• Floppy drives
• Hard drives 

Wire Jumper Assemblies 

Wire jumper cable assembly is a suitable Cable assembly for connecting base stations and antennas. In this assembly, there is no specific configuration of the wires. Wires jump from one place to another as per the name of the assembly.

White jumper assemblies are top-notch assemblies for their budget-friendly design, materials, and Cable assembly manufacturing. Once you get your hand in a wire assembly, you can expect optimal connectivity, an easy installation process, and a long self-life from the assembly.

Military Assemblies 

Military assemblies must be strong and rigid enough to survive in dangerous situations. These assemblies provided by us are rugged, dependable, and strong. Additionally, our military assemblies provide high-quality performance, fast transmission, and high signal integrity. 

Military cable assemblies mostly get used in: 

• Military ground equipment
• Field communication links
• Inter-shelter communication 
• Airborne systems 
• Marine systems 
• Remote weapon control links 

Medical Cable Assemblies

Medical cable assemblies are largely used in the medical field. We work with each type of medical jacketed cable, including unshielded, shielded, and multi-shielded. The major applications of medical cable assemblies are: 

• Imaging systems like CT, CAT, scan, etc. 
• Monitoring system

All medical cable assemblies have to be chemical resistant, EMI suppressant, and must have huge traceability. 

Cable Assemblies Applications 

The applications of cable assemblies are widespread. Finding a single place that does not use Cable assembly from medical sectors to the military is next to impossible. Now, let’s have a look at some of the applications of cable assemblies. 

Flat panel displays: Flat panel displays are used all over the world. People from everywhere use flat panel displays in commercial industries, industrial purposes, etc. From the household TV to the workplace display, all are examples of flat panel displays. We provide a wide variety of custom cable assemblies to our customers from different fields. 

Automotive: With the growth of technology, the abrupt growth of vehicles and automotive devices is without a doubt surprising. Car developers are using various new technology and features for providing safety, security, and looks to the cars of this era. As one of the best cable assembly manufacturers, we provide all kinds of facilities in Cable assembly manufacturing for vehicles’ navigation systems. It controls the movement and functionalities of a vehicle.

Military purposes: Military is a field that needs strong and reliable communication services, durable devices. They need custom cable assembly for telecommunication, Military ground equipment, inter-shelter communication, airborne system, remote weapon control link, etc.

Medical sectors: Cable assembly manufacturers provide reliable, durable, precise, and good quality custom cable assembly for monitoring, testing, and providing solutions to patients. These include: 

• Medical imaging system
• X-ray and MRI
• Electro surgery cables
• Ultra Sound probes
• Telemetry cables
• Pulse oximeters 

Some other uses of cable assemblies are: 

• Automobile wiring 
• New house construction 
• LED lighted apparels accessories, costumes
• Computers and electronics 
• Drones

Why prefer us for Custom Cable Assembly Manufacturers? 

For those, who are searching for a custom cable assembly manufacturer, we are always here. We are one stop for all your Custom cable manufacturing needs. Regardless of the complexity of the process, we provide 100% quality works to our customers from every niche.

With us, you can get your hand into each type of cable assemblies including multi-layered, wire jumper, military, medical, etc. Additionally, we manufacture products within your budget without jeopardizing the product quality. In case you are in doubt, make sure to contact us without wasting any more time.