Your Design, Our Expertise

Custom Cable Assembly

Fully customized cable assembly solutions tailored to your exact requirements. From concept to production, we bring your designs to life.

TL;DR — Custom Cable Assembly at a Glance

  • No MOQ — order 1pc prototype or 500,000+ annual volume
  • 48-hour prototyping — validate your design before committing to production
  • ISO 9001 + IATF 16949 certified — automotive-grade quality for every project
  • 12+ connector brands — Molex, TE, JST, Amphenol, Hirose, Phoenix Contact, Deutsch
  • Quote in 24 hours — send drawings, specs, or just a concept description
0
Minimum Order
48h
Prototype Time
DFM
Support Included
100%
Testing
What We Offer

Custom Capabilities

Everything you need to bring your custom cable assembly from concept to reality.

Design Support

Engineering assistance from concept to production-ready design

Rapid Prototyping

48-hour prototype capability for fast design validation

Documentation

Complete technical documentation and work instructions

Component Sourcing

Access to all major connector and cable manufacturers

Custom Tooling

Application-specific tooling and test fixtures

Scalable Production

From 1 piece to 500,000+ with no minimum order

How We Work

Our Process

A proven process for custom cable assembly development and production.

1

Requirements Review

Share your drawings, specifications, or concept. We'll review and provide feedback.

2

Design Optimization

Our engineers provide DFM analysis and optimization recommendations.

3

Prototype Development

Rapid prototype production for design validation and testing.

4

Production Setup

Tooling, fixtures, and production documentation preparation.

5

Manufacturing

Quality-controlled production with 100% testing.

6

Delivery & Support

On-time delivery with ongoing support for your program.

Full Customization

Everything Is Customizable

Every aspect of your cable assembly can be tailored to your specific requirements. We work with you to optimize the design for your application, manufacturing efficiency, and cost targets.

Cable Options

  • Cable type & gauge
  • Shielding options
  • Jacket materials
  • Multi-conductor
  • Custom colors

Connector Options

  • Connector selection
  • Termination type
  • Backshells
  • Strain relief
  • Overmolding
Start Your Custom Project
Cable Assembly Production Area

What to Include in Your Request

Required Information

  • Drawing or schematic (any format)
  • Connector requirements
  • Cable specifications
  • Quantity needed

Helpful Additions

  • Sample of existing cable
  • Application description
  • Environmental conditions
  • Target price point

Don't have complete specifications? No problem - we can work from concept descriptions and provide recommendations.

What We Build

Cable Types

We manufacture custom versions of all cable assembly types.

Power Cables

AC/DC, high current

Data Cables

Ethernet, serial, signal

Coaxial Cables

RF, antenna, video

Ribbon Cables

Flat, FFC, FPC

USB Cables

All types and speeds

M12/Industrial

Sensors, automation

Overmolded

Sealed, strain relief

Specialty

Unique requirements

Your Partner for Custom Cable Assembly Manufacturing

As a leading custom cable assembly manufacturer, OurPCB transforms your unique requirements into production-ready cable solutions. Our cable assembly expertise spans every cable type, connector brand, and industry application, delivering tailored solutions that meet your exact specifications.

Our engineering team provides comprehensive design for manufacturing (DFM) support from initial concept through production. We offer connector selection guidance, cable sizing optimization, and complete technical documentation. With 48-hour rapid prototyping, you can validate your design before committing to production volumes, then use our production-ready cable assembly release path to lock the drawing, BOM, test plan, and work instruction for repeat orders.

We manufacture all cable types including power cables for AC/DC applications, data cables for networking and signal transmission, coaxial assemblies for RF applications, and USB cables for device connectivity. Our component sourcing includes all major manufacturers: Molex, TE Connectivity, JST, and Amphenol.

Industries served include automotive, medical devices, industrial automation, and robotics. Our ISO 9001 and IATF 16949 certified facilities ensure consistent quality across every custom cable project.

With no minimum order quantity and scalable production from 1 piece to 500,000+, we support projects at every stage. 100% electrical testing and complete documentation ensure reliable performance. If your custom cable must follow North American safety file requirements, our UL CSA certified cable assembly support adds approved-material, label, hipot, and traceability controls to the RFQ. Contact us today to start your custom cable assembly project.

Transparent Costs

Pricing & Lead Time

Indicative pricing by assembly complexity. Exact quotes provided within 24 hours.

Assembly TypeUnit Price RangePrototype Lead TimeProduction Lead Time
Simple (2-connector, single cable)$2 – $5 /unit at volume48 hours2 weeks
Standard (multi-conductor, shielded)$5 – $15 /unit at volume5–7 days2–3 weeks
Complex (multi-branch, overmolded)$15 – $50 /unit at volume7–10 days3–4 weeks
High-spec (MIL-SPEC, medical, IP67+)$50 – $80+ /unit at volume10–15 days4–6 weeks

Prices are indicative for volume orders (1,000+ units). Prototype/sample pricing may vary. No hidden tooling fees for standard assemblies. Expedited service available — contact us for rush quotes.

Standards We Meet

Quality & Certifications

Automotive-grade quality management with industry-specific compliance.

ISO 9001:2015

Quality Management System

All manufacturing

IATF 16949:2016

Automotive Quality Standard

Automotive projects

IPC/WHMA-A-620

Cable & Harness Workmanship

All assemblies

UL / CSA

Safety Certification

Power & medical cables

RoHS / REACH

Environmental Compliance

All products

MIL-SPEC

Military Standards

Defense applications

Testing & Inspection

  • 100% Continuity testing
  • Hi-pot (dielectric withstand)
  • Insulation resistance
  • Pull-force testing
  • Visual inspection (IPC-A-620)
  • Custom functional tests
Real Project Snapshot

From the Case Bank

industrial · 2025-2026
Scenario

A German industrial electrical systems integrator required cable harnesses for a high-volume annual program but faced sourcing constraints on specified connectors.

Challenge

The originally specified STOCKO connectors faced procurement limitations, and the required PTC components (EPCOS B59100A1080-A40) had a long 12-14 week lead time, threatening the overall project timeline for a 200kpcs/year program.

Solution

Proposed Lumberg connectors as a qualified alternative to STOCKO. Provided detailed specification comparisons and emphasized Lumberg's shorter MOQ and better delivery times to offset the PTC lead time bottleneck, while remaining transparent about the slightly higher price point of the alternative.

Result

The customer accepted the alternative for evaluation, agreeing to sample the Lumberg-based assemblies, which kept the high-volume annual program viable despite initial component sourcing bottlenecks.

Concrete Numbers
  • 100kpcs/year per product (200kpcs total annual volume)
  • PTC model: EPCOS B59100A1080-A40
  • PTC lead time: 12-14 weeks
  • Connectors evaluated: STOCKO vs. Lumberg
Real Project Snapshot

Prototype to Mass Production — Smart Hardware

smart-hardware · 2024-2025
Scenario

A US industrial smart-device distributor needed to scale a diverse range of custom cable assemblies from initial prototyping to high-volume mass production.

Challenge

Frequent design changes (cable lengths, shielding requirements, connector models) combined with a wide range of order volumes — from dozens of samples to tens of thousands of units across 10+ SKUs.

Solution

Provided agile sample turnaround and flexible manufacturing processes, accommodating rapid design iterations while smoothly transitioning to volume production for multiple SKUs (Float sensor, Ethernet, Speaker cables).

Result

Secured a multi-million dollar annual revenue program across multiple product lines, demonstrating capability to handle high-mix scaling from prototype to mass production.

Concrete Numbers
  • Order volumes: dozens (samples) to 20,000+ units per SKU
  • 10+ active SKUs managed simultaneously
  • Multi-million dollar annual program secured
Real Project Snapshot

From R&D Samples to 10K Annual Volume

currency-technology · 2024-2025
Scenario

A subsidiary of a global currency-technology OEM required custom cable assemblies for banknote-processing R&D, starting with small prototype batches and scaling to mass production.

Challenge

Managing the transition from 10-20 piece sample orders to 500-unit MOQ mass production while maintaining consistent quality and meeting aggressive 2-3 week lead times.

Solution

Provided flexible sample manufacturing via streamlined payment channels for fast procurement, followed by structured mass production setup with MOQ 500 sets, accommodating annual volumes of 5-10K units.

Result

Successfully transitioned from prototype to mass production, securing a multi-year repeat program with annual volumes reaching 5,000-10,000 units.

Concrete Numbers
  • Sample qty: 10-20 pieces
  • Production MOQ: 500 sets
  • Annual volume: 5,000-10,000 units
  • Standard lead time: 2-3 weeks
Real Project Snapshot

15-Day Rush Delivery for EV Harness Prototype

automotive · 2025
Scenario

A US EV automotive OEM required an urgent NPI prototype run for a new vehicle harness package with Amphenol connectors.

Challenge

50 units needed within 15 days of PO issuance, requiring rapid procurement of authorized Amphenol connectors alongside expedited manufacturing.

Solution

Fast-tracked the production schedule, secured Amphenol connector authorization and procurement, and coordinated expedited logistics to meet the 15-day deadline.

Result

Delivered the initial prototype batch on time, securing the customer's trust and a follow-on multi-PO repeat program for the vehicle platform.

Concrete Numbers
  • 50 units delivered
  • 15-day lead time (PO to delivery)
  • Amphenol authorized connectors
  • Follow-on multi-PO repeat program secured
Common Questions

Custom Cable Assembly FAQ

To provide an accurate quote, we need: drawings or schematics (if available), connector part numbers or requirements, cable specifications (type, gauge, length), quantity requirements, and any special requirements (shielding, IP rating, temperature range). We can also work from concept descriptions or samples if detailed drawings aren't available. Most quotes are returned within 24 hours.

Yes, our engineering team provides full design support from concept to production-ready documentation. We offer connector selection guidance, cable sizing optimization, routing analysis, and design for manufacturing (DFM) review. We create complete technical drawings and BOM for customer approval before production.

We have no minimum order quantity — you can order as few as 1 piece for prototyping. This allows you to validate your design before committing to volume production. We support the full range from 1pc prototypes to 500,000+ annual programs.

Prototype turnaround is 48 hours for simple assemblies, 5-7 business days for complex designs. Standard production lead time is 2-3 weeks. Expedited service is available depending on complexity and component availability. We provide specific lead times with every quote.

Our facilities are ISO 9001 and IATF 16949 certified. We manufacture to IPC/WHMA-A-620 workmanship standards. Depending on application, we support UL, CSA, CE, RoHS, and MIL-SPEC requirements. All assemblies undergo 100% electrical testing (continuity, hi-pot, insulation resistance).

We source from all major connector manufacturers including Molex, TE Connectivity, JST, Amphenol, Hirose, Phoenix Contact, Deutsch, and 12+ other brands. We can also work with customer-supplied or customer-specified components.

Pricing depends on connector complexity, cable type, length, shielding, and volume. Simple 2-connector assemblies start around $2-5/unit at volume. Complex multi-branch harnesses with overmolding range $15-80+/unit. We provide detailed cost breakdowns with every quote — no hidden tooling fees for standard assemblies.

Yes, we manage the full lifecycle from 1pc prototypes through high-volume mass production (500,000+ units/year). Many of our customers start with small prototype batches for design validation, then scale to production volumes. Our flexible manufacturing supports high-mix, low-volume (HMLV) as well as dedicated high-volume lines.

Every cable assembly undergoes 100% electrical testing including continuity verification, hi-pot (dielectric withstand), and insulation resistance. Additional tests available include pull-force testing, flex cycling, environmental stress screening, and custom functional tests per customer specifications.

Absolutely. We support agile NPI (New Product Introduction) processes with rapid design iteration capability. Our engineering team accommodates changes to cable lengths, connector models, shielding requirements, and pinouts throughout the development cycle without restarting the quoting process from scratch.

Ready to Start Your Custom Project?

Send us your requirements and receive a detailed quote within 24 hours. No minimum order quantity.