Custom Cable Assembly Manufacturer for USB & OEM Harness Builds
Contract manufacturing for custom cable assemblies, USB cable assemblies, and wire harnesses from prototype to production.
Send your drawing, pinout, sample, or BOM and our team will quote a buildable assembly with connector sourcing, crimping, soldering, labeling, sleeving, and 100% electrical test coverage.
Need UL/CSA-ready export cable assemblies?
For equipment programs that require UL-recognized wire styles, CSA-compatible materials, hi-pot testing, and certificate records, our dedicated UL CSA certified cable assembly service reviews the compliance BOM before first article release.
Need compact JST connector harnesses?
For XH, PH, SM, VH, ZH, SH, PA, and JWPF builds, our JST connector harness service confirms the exact series, pin map, crimp setup, and first-article test plan.
What is Cable Assembly?
Cable assembly is the process of building finished interconnects from specified wire, cable, connectors, contacts, labels, and protection materials. As a contract assembler, we manufacture custom cable assemblies and USB cable assemblies to your electrical, mechanical, and documentation requirements; we do not sell raw cable or standalone connectors as catalogue products.
Fast Turnaround
Prototypes ready in 2-3 weeks. Production runs completed on schedule with real-time tracking.
Quality Certified
ISO 9001:2015 certified facilities with rigorous testing protocols.
Custom Design
In-house engineering team to design cable assemblies tailored to your exact specifications.
Global Delivery
Manufacturing facilities in China and Philippines. Ship worldwide from Australia.
Flexible MOQ
From single prototypes to millions of units. No minimum order quantity restrictions.
100% Testing
Every cable assembly undergoes continuity, insulation resistance, and hi-pot testing.
Technical Capabilities
Wire Specifications
Assembly Options
Capability matrix by build type
“Cable assembly” covers several distinct build types, and each one drives a different wire range, termination method, and test plan. This page is the finished-interconnect entry point; for a multi-branch loom with breakouts, see our OEM wiring harness capability. The ranges below sit within the wire and assembly specifications above.
| Build type | Typical wire | Termination | Standard testing | Dedicated page |
|---|---|---|---|---|
| Signal & data cables USB, RJ45, HDMI, D-Sub | ~AWG 32–24 | Crimp, IDC, or molded strain relief | 100% continuity; hipot where specified | Overmolding |
| Power cables | ~AWG 18–4/0 | Crimp lugs, ring/spade terminals | Continuity, hipot, and pull-force to spec | This page |
| Ribbon / IDC | Flat cable, fixed pitch | Mass IDC termination | 100% continuity | IDC ribbon |
| RF / micro-coax | Coaxial | Solder or crimp coax connectors | Continuity; VSWR/insertion loss to spec | Micro-coax |
| Multi-branch OEM harness | Mixed AWG | Crimp + breakouts + protection | 100% continuity; hipot where specified | OEM harness |
From drawing to test report
Every build runs against your documentation, and every build comes back with evidence. A typical program produces:
- A DFM review of your drawing, BOM, and connector callouts before the first unit is built.
- A first-article inspection (FAI) against the released drawing.
- 100% electrical test per unit — continuity, plus hipot and pull-force where the spec calls for them.
- Retained test records and a certificate of conformance with the shipment.
Send the exact wire, connector, length, and test requirements and we quote against them rather than a generic part.
What we build — and the exceptions
We assemble finished interconnects to your specification, from a single jumper to a multi-branch harness, terminated by crimp, solder, IDC, or overmold, in AWG 32 to 4/0 and lengths from 10 mm to 50 m. To keep scope honest, a few things sit outside it:
- We are a contract assembler — we do not sell raw bulk cable or standalone connectors as catalogue items, and we do not extrude cable.
- We focus on commercial and industrial programs; ITAR-controlled defense and aerospace builds are out of scope.
- Specialised approvals or very high volumes are quoted case by case against your actual requirement.
Our Manufacturing Process
Consultation
Discuss your requirements and specifications
Design
Engineering team creates custom design
Prototype
Build and test prototype units (2-3 weeks)
Production
Mass manufacture to your schedule
Quality Test
100% testing and inspection before shipping
How a typical professional cable assembly manufacturing program runs with us
This is an illustrative description of a representative project type, not a specific customer engagement. As a contract assembler we do not publish customer-identifiable data.
Frequently Asked Questions
What is the minimum order quantity for cable assemblies?▼
We have no minimum order quantity. Whether you need a single prototype or millions of units, we can accommodate your requirements.
How long does it take to manufacture cable assemblies?▼
Prototype cable assemblies typically take 2-3 weeks. Production runs vary based on quantity and complexity, but we provide detailed timelines during the quote process.
What certifications do your cable assemblies have?▼
Our facilities are ISO 9001:2015 certified. We can also manufacture to industry-specific standards like CE, AS/NZS, and RoHS upon request.
Can you design custom cable assemblies?▼
Yes! Our in-house engineering team can design cable assemblies from scratch based on your specifications, or modify existing designs to meet your needs.
What types of connectors do you support?▼
We work with over 1,000 connector types including D-Sub, USB, HDMI, RJ45, circular connectors, terminal blocks, and custom connectors from major manufacturers.
Do you test every cable assembly?▼
Yes. 100% of our cable assemblies undergo continuity testing, insulation resistance testing, and hi-pot testing before shipping. Additional testing can be provided upon request.
Where are your manufacturing facilities located?▼
We have manufacturing facilities in China (rapid prototyping) and Philippines (volume production), with sales and support based in Melbourne, Australia.
Have more questions?
Contact Our TeamRelated Resources
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Industry Applications
Get a Cable Assembly Quote
Send your drawing, wire list or BOM — an engineer replies with a quote and lead time within 24 hours.
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