Complex Custom Wire Harness for Consumer Electronics OEMs
B2B engineering partner for high-value, custom wire harness assemblies. We specialize in complex, multi-conductor integrated cable solutions for consumer electronics brands - not simple off-the-shelf cables. ISO & IATF certified with global component sourcing capabilities.
🔧 Engineering Design Support | 🌏 Global Component Sourcing | 🏭 Turnkey Manufacturing
B2B Custom Harness Only - Not Retail Cables
- ✓ Complex custom wire harness design & manufacturing
- ✓ Multi-conductor integrated cable assemblies
- ✓ Overmolded & custom connector solutions
- ✓ Global component sourcing services
- ✓ Engineering design support (DFM, prototyping)
- ✓ B2B OEM/ODM partnerships
- ✕ Simple standard HDMI cables (commodity products)
- ✕ Basic USB charging cables (low value-add)
- ✕ Off-the-shelf audio/video cables
- ✕ Retail/consumer direct sales
- ✕ Stock/ready-made cable inventory
Complex Custom Harness Solutions - Not Simple Cables
We don't make simple HDMI or USB cables. We engineer high-value, complex wire harnesses with custom connectors, overmolding, and integrated functionality for consumer electronics brands.
Multi-Function Integrated Harness
Complex assemblies combining power, data, audio, and control signals in one custom harness. Overmolded junctions, custom connector configurations.
Smart Device Internal Harness
Custom internal wire harnesses for smartphones, tablets, wearables. Ultra-thin FFC/FPC integration, board-to-board connectors, flex circuits.
Gaming & VR/AR Harness
Specialized harnesses for gaming controllers, VR headsets, AR devices. Lightweight, high-flex materials, custom molded strain reliefs.
Audio Equipment Custom Harness
Professional audio harnesses with shielded twisted pairs, custom connector assemblies, balanced signal transmission for premium audio devices.
IoT & Smart Home Harness
Custom harnesses for smart home devices, IoT sensors, connected appliances. Compact designs with environmental protection and custom enclosures.
Display & Monitor Harness
Complex internal harnesses for monitors, TVs, digital signage. High-speed differential pairs, EMI shielding, power distribution integration.
Applications We Serve
Trusted cable assembly partner for leading consumer electronics brands worldwide
Smart Devices
Smartphones, Tablets, E-readers
Audio Equipment
Headphones, Speakers, Soundbars
Video Equipment
TVs, Monitors, Projectors
Gaming Consoles
Xbox, PlayStation, Nintendo
Wearables
Smartwatches, Fitness Trackers
Home Appliances
IoT Devices, Smart Home
Computers
Desktops, Laptops, Peripherals
VR/AR Headsets
Virtual Reality, Augmented Reality
World-Class Manufacturing Capabilities
Advanced equipment and skilled technicians ensuring precision, consistency, and quality
Automated Terminal Crimping
High-precision automatic crimping machines ensure consistent terminal connections with ±0.02mm tolerance
Wiring Assembly Line
Dedicated assembly lines for HDMI, USB, and custom cable production with real-time quality monitoring
Testing Equipment
100% electrical testing, hi-pot testing, signal integrity testing, and continuity verification
Precision Wire Cutting
CNC wire cutting and stripping machines for accurate length control and minimal wire waste
Quality Control Area
Dedicated QC stations with vision inspection systems and dimensional measurement tools
Skilled Technical Team
IPC-certified technicians with expertise in consumer electronics cable assembly standards
Technical Specifications
Comprehensive specifications for consumer electronics cable assemblies
Cable Specifications
Connector Options
Key Features & Advantages
Engineering excellence delivering superior performance for consumer electronics
High-Speed Data Transmission
Support for latest data transfer standards including USB 4.0 (40Gbps), HDMI 2.1 (48Gbps), Thunderbolt 3/4, DisplayPort 1.4.
- USB 4.0, USB 3.2, USB 3.1 Gen 2
- HDMI 2.1 with eARC, VRR, ALLM
- DisplayPort 1.4 with DSC
- Ethernet Cat6a, Cat7 gigabit speeds
Compact & Flexible Design
Ultra-thin, lightweight cables ideal for modern consumer devices. Flexible materials withstand repeated bending and movement.
- Slim profile cables for space-constrained devices
- Flexible TPE, silicone jacket materials
- Reinforced strain relief at connector ends
- Tangle-free braided cable options
Durable & EMI Protected
Superior shielding reduces electromagnetic interference. Durable materials ensure long product lifespan and customer satisfaction.
- Triple-layer shielding (foil + braid + drain wire)
- EMI/RFI protection for clean signal transmission
- Abrasion-resistant outer jacket
- RoHS, REACH, CA Prop 65 compliant materials
Global Component Sourcing Capabilities
Beyond manufacturing - we provide comprehensive global sourcing services for custom connectors, specialty materials, and hard-to-find components
Custom Connector Sourcing
Access to global connector suppliers - Molex, TE Connectivity, JST, Amphenol, Hirose. We source custom connectors that match your exact specifications, even for low volumes.
Cost Optimization
Alternative component recommendations to reduce costs. We identify equivalent parts from multiple suppliers, negotiate better pricing, and help you optimize your BOM.
Supply Chain Management
Inventory management, JIT delivery, and buffer stock services. We handle component procurement so you can focus on product development and sales.
What We Can Source For You:
- • Custom USB-C, Lightning
- • Board-to-board, FPC/FFC
- • Waterproof connectors
- • Magnetic connectors
- • Ultra-thin coaxial
- • High-flex silicone
- • Shielded twisted pair
- • Specialty jacket materials
- • EMI/RFI shielding
- • Strain relief boots
- • Custom molded parts
- • Ferrite cores
- • Medical-grade silicone
- • Halogen-free materials
- • UV-resistant jackets
- • Custom color options
Why Choose OURPCB for Complex Custom Harness?
Engineering-driven approach with turnkey solutions from design to delivery
In-house engineers provide DFM review, custom harness design, and prototyping support
Access to worldwide component suppliers - we source custom connectors and specialty materials
Overmolding, potting, ultrasonic welding, and advanced harness assembly capabilities
Automotive-grade quality systems with full traceability and PPAP documentation
Quality Assurance & Certifications
ISO & IATF certified manufacturing with comprehensive quality systems
ISO 9001:2015 Certified
Internationally recognized quality management system ensuring consistent product quality and customer satisfaction.
IATF 16949:2016 Certified
Automotive quality management certification demonstrating capability for high-reliability electronics manufacturing.
Quality Commitment
Delivery Capability
Business Terms
Compliance & Standards
Custom Cable Assembly Process
From concept to production - a seamless journey with engineering support every step
Design Consultation
Share your requirements, drawings, or samples. Our engineers review and provide recommendations.
Quote & Design
Receive detailed quote quickly. DFM review and custom cable design if needed.
Prototyping
Fast prototype production. Functional testing and validation before mass production.
Mass Production
Automated production with in-line quality checks. Real-time production updates.
Testing & Delivery
100% electrical testing, packaging, and on-time delivery with full documentation.
Customer Success Stories
Trusted by leading consumer electronics brands worldwide
Smart Device Manufacturer
"OURPCB delivered custom USB-C cables for our flagship smartphone. Their 5-day prototype turnaround helped us meet our product launch deadline. Zero field failures in 500K+ units shipped."
Gaming Peripheral Company
"Switched from European supplier to OURPCB for HDMI 2.1 cables. Saved 35% on cost without compromising quality. ISO certification gave us confidence. Customer return rate improved from 0.8% to 0.2%."
Audio Equipment Brand
"OURPCB's custom audio cables for our premium headphone line exceeded expectations. Gold-plated connectors, superior shielding, and flexible design. 2-year warranty shows their confidence in quality."
Frequently Asked Questions
Common questions about our consumer electronics cable assemblies
What types of consumer electronics cables can you manufacture?
We manufacture HDMI cables (1.4, 2.0, 2.1), USB cables (2.0, 3.0, 3.1, USB-C), DisplayPort cables, audio/video cables (3.5mm, RCA, optical), Ethernet cables (Cat5e-Cat7), and custom power cables. All cables can be customized for length, connector type, shielding, and jacket material.
What is your minimum order quantity (MOQ)?
We offer flexible MOQ, making us ideal for startups, prototyping, and small-batch production. For established OEMs with recurring orders, we provide favorable terms and volume pricing. Contact us to discuss your specific requirements.
How fast can you deliver prototype cables?
Prototype lead time varies depending on complexity. We prioritize fast turnaround for prototype projects. Rush service available for urgent projects. Contact us with your specific requirements for an accurate timeline.
Do you support custom cable designs?
Yes. Our engineering team provides free design consultation, DFM review, and custom cable design services. We can work from your drawings, samples, or specifications to create the exact cable you need.
Are your cables compliant with industry standards?
All cables are manufactured to relevant industry standards (HDMI 2.1, USB-IF, DisplayPort, etc.) and are RoHS, REACH, and UL compliant. We can provide test reports and certifications as needed.
What testing do you perform on cables?
100% electrical continuity testing, hi-pot testing (dielectric strength), signal integrity testing for high-speed cables, visual inspection, and dimensional verification. Additional testing available: EMI/EMC, bend cycle, pull force, temperature cycling.
Can you handle high-volume production?
Yes. We have large-scale production capacity and support both small-batch and high-volume production with consistent quality and on-time delivery. Contact us to discuss your volume requirements.
What is your typical lead time for mass production?
Production lead time varies depending on order quantity and complexity. We offer competitive lead times for both small and large orders. Contact us with your specific requirements for an accurate production schedule.
Do you provide samples for evaluation?
Yes. We provide prototype samples for evaluation before mass production. Sample cost depends on cable complexity and can be discussed based on your production volume plans.
What are your payment terms?
We offer flexible payment terms based on order volume and customer relationship. Credit terms available for qualified OEMs. For new customers, deposit arrangements can be discussed. We accept wire transfer, PayPal, and major credit cards.
Do you offer warranty on your cables?
Yes. We provide comprehensive warranty on all cable assemblies against manufacturing defects. Extended warranty programs available for high-volume customers. We stand behind our quality. Specific warranty terms discussed based on your application.
Can you ship internationally?
Yes. We ship worldwide via DHL, FedEx, UPS. Competitive shipping rates with volume discounts available. Full export documentation and HS codes provided for international shipments.
Cost Optimization & Supply Chain Solutions
Beyond manufacturing - strategic support to reduce costs and ensure supply continuity
Long-Term Cost Reduction
Strategic component optimization for sustainable savings
Alternative Component Sourcing
Our sales managers can recommend cost-effective alternative models from Chinese suppliers that meet the same specifications - often reducing component costs significantly.
Custom Mold Development
For high-volume requirements, we can develop custom molds tailored to your exact needs. While there's an upfront investment, this dramatically reduces per-unit costs for long-term production runs.
Inventory Management Services
Never miss a deadline with our stocking solutions
Pre-Stocking for Critical Orders
If you have strict delivery requirements or seasonal demand peaks, we recommend pre-stocking key assemblies. Our extensive factory space can accommodate your inventory needs.
Material Management Support
For your most important orders, we provide comprehensive material management - ensuring components are ready when production begins, eliminating supply chain delays.
Speak with Our Melbourne Manager
Discuss cost optimization, inventory solutions, and custom component sourcing with Mark, our local Australia manager based in Melbourne.
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Ready to Get Custom Consumer Electronics Cables?
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ISO 9001 & IATF 16949 Certified | RoHS & REACH Compliant | Comprehensive Warranty