Understanding Cable Assembly: Types, Applications, and Solutions

Cable assembly plays a crucial role in the printed circuit board assembly process. It involves the collection and connection of multiple wires during PCB assembly. But what exactly is cable assembly? Let’s delve into its definition, processes, applications, and classifications.

If you’re curious about all things cable assembly, this article is a must-read.

Defining Cable Assembly

Cable assembly is essentially a grouping of wires or cables interconnected into a single unit. It is an integral part of PCB assembly and is typically carried out through hand soldering by authorized companies. When selecting a company for cable assembly, always verify their certification.

Overmolding is a specialized capability offered by many electronic manufacturing services companies. This process involves developing tiny parts using multiple layers and components, with the initial layer being coated with various elements during creation.

Our Top Cable Assembly Services

Cutting and Organizing Wires: As professional cable assembly manufacturers, we prioritize the meticulous cutting and organizing of wires using 100% automatic devices. Our process includes cutting, stripping, tin dipping, and crimping for both single and multi-core wires.

Crimped Cable Assemblies: In this stage, prepared wire segments are crimped using automated crimping devices and various tools from major manufacturers like TE Connectivity, Molex, Amphenol, JST, Hirose, and ITT Cannon.

Cable Looms and Harness Assembly: We offer a wide range of cable assembly services, including multi-layered, coaxial, battery, flat ribbon, wire jumper, military, and medical cable assemblies, catering to diverse industries.

Featured Cable Assembly Solutions

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

Brief Overview

Various types of cable assemblies are prevalent in the electronics industry, ranging from multi-layered assemblies to wire jumpers, each with unique constructions, components, and applications. As a leading cable assembly manufacturer, we offer seven primary custom cable manufacturing services.

Types of Cable Assemblies

• 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

Explore the different types of cable assemblies and their applications below.

Multi-conductor Cable Assemblies

A multi-conductor cable assembly contains multiple conductors within a single cable, ranging from two to over twenty-five conductors, enclosed in an insulation sheath. These assemblies find applications in communication systems, data transmission, audio systems, high voltage current transmission, and remote signaling communication. Due to their multi-layered design, they offer strength, durability, consistent power flow, high-quality data transmission, and longevity.

Coaxial Cable Assemblies

Coaxial cable assemblies, also known as RF or Rflex cable assemblies, are constructed using various connectors such as BNC, TNC, SMA, MCX, SMP, MMBX, MMCX, N-type, SMB, and UHF, depending on the application. These assemblies, available in rigid, flexible, or semi-rigid forms, are commonly used for transmitting radio frequency signals in the multi-megahertz range. They are utilized in military, aerospace, transportation, radiofrequency signals, communicators, and test equipment applications.

Solving Your Connectivity Needs with Specialized Cable Assemblies

Sensors

Coaxial cable assemblies are known for their versatility and high-data transfer capabilities, making them ideal for various applications with low error rates.

Battery Cable Assemblies

Battery cable assemblies play a crucial role in connecting batteries to electric systems, offering resistance to moisture, vibration, and harsh environments. These assemblies are commonly used in industries such as medical, automotive, mariner, manufacturing, and military.

IDC Flat Ribbon Cable Assemblies

IDC flat ribbon cable assemblies are flat and wide, allowing for mass termination to insulation-displacement connectors. These assemblies are versatile with features like various pin counts, low profile design, and compatibility with internal peripherals like CD drives and hard drives.

Wire Jumper Assemblies

Wire jumper cable assemblies provide a flexible solution for connecting base stations and antennas, offering optimal connectivity, easy installation, and durability. These assemblies allow wires to jump from one point to another seamlessly.

Military Assemblies

Military cable assemblies are designed to withstand harsh conditions, providing rugged and dependable connectivity for military ground equipment, field communication links, and inter-shelter communication. These assemblies offer high-quality performance, fast transmission, and strong signal integrity.

A Wide Range of Cable Assembly Applications

• Airborne systems
• Marine systems
• Remote weapon control links

Exploring Medical Cable Assemblies

Medical cable assemblies play a crucial role in the healthcare industry, offering solutions for various medical applications. These assemblies come in different types, including shielded, unshielded, and multi-shielded cables, and are essential for:

• Imaging systems like CT and CAT scans
• Monitoring systems

These assemblies are designed to be chemical resistant, EMI suppressant, and highly traceable to meet medical standards.

Applications of Cable Assemblies

Cable assemblies find extensive use across different sectors, from medical facilities to military operations. Here are some common applications:

Flat Panel Displays

Flat panel displays are ubiquitous in commercial and industrial settings, from household TVs to workplace monitors. Our custom cable assemblies cater to a wide range of display needs.

Automotive Industry

As technology advances, vehicles incorporate new features for safety and functionality. Our cable assemblies support navigation systems and control various aspects of vehicle operations.

Military Applications

The military relies on robust communication systems and durable equipment. Custom cable assemblies are crucial for telecommunication, ground equipment, and other military operations.

Medical Sector

We specialize in providing high-quality custom cable assemblies for medical imaging, X-rays, MRI, and other medical equipment. Our solutions ensure precision and reliability in patient care.

• Electro surgery cables
• Ultra Sound probes
• Telemetry cables
• Pulse oximeters

Other Uses of Cable Assemblies

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

Choose Us for Custom Cable Assembly Manufacturing

If you’re in need of custom cable assembly manufacturing, look no further. We offer comprehensive solutions tailored to your specific requirements. Our expertise covers a wide range of cable assemblies, ensuring quality and affordability without compromise. Contact us today to discuss your needs.

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