Insulation Displacement Connector Solutions

IDC Cable Assembly

Custom IDC cable assemblies with mass termination technology. From single prototypes to high-volume production — flat ribbon cables, breakout cables, and transition assemblies built to your specifications.

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Max Pin Count

1.27mm

Min Pitch

48h

Prototype Lead

100%

Tested

Complete IDC Range

IDC Connector Types We Process

We manufacture cable assemblies with all major IDC connector styles and pitch configurations.

Type

Pitch

Pin Range

Application

Standard IDC

2.54mm (0.1")

6 to 64 pins

Most common for general electronics and PCB interconnects

Mini IDC

2.0mm

6 to 40 pins

Compact designs where board space is limited

Micro IDC

1.27mm (0.05")

10 to 68 pins

High-density applications, SCSI, and telecom equipment

D-Sub IDC

2.77mm

9 to 37 pins

DB9, DB15, DB25 with IDC termination for quick assembly

Card Edge IDC

2.54mm

10 to 50 pins

PCB edge connections for daughterboard and backplane

DIN 41612 IDC

2.54mm

32 to 96 pins

Eurocard/VMEbus rack-mount systems and industrial controls

What We Offer

IDC Assembly Capabilities

Mass termination technology combined with rigorous testing for reliable, cost-effective cable assemblies.

Mass Termination

Simultaneous termination of all conductors in a single press stroke

Ribbon Cable Processing

Precision cutting, stripping and folding of flat ribbon cables

Pin-to-Pin Continuity

100% electrical testing of every connection point after assembly

Strain Relief Options

Integrated strain relief clips and locking mechanisms available

Custom Configurations

Point-to-point, daisy chain, breakout, and transition cables

High-Density Termination

Fine-pitch 1.27mm IDC for high pin-count applications

Why Choose IDC

Fast, Reliable Mass Termination

IDC technology eliminates wire stripping and individual termination. All conductors connect simultaneously in a single press operation, cutting assembly time by up to 80% compared to crimp or solder methods.

No wire stripping required
All pins terminated in one step
Consistent, repeatable connections
Lower assembly cost per unit
Color-coded conductor identification
Keyed connectors prevent mis-mating
Polarized housings for correct orientation
Stackable for board-to-board connections

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Industry Applications

Industrial Controls

PLC I/O modules, relay boards, panel wiring

Telecommunications

Patch panels, distribution frames, network switches

Computer & Data

Hard drive cables, motherboard connections, SCSI

Medical Devices

Diagnostic equipment, patient monitoring internals

Test & Measurement

Bench instruments, data acquisition systems

Consumer Electronics

Printers, displays, internal board-to-board links

Technical Data

IDC Cable Assembly Specifications

Standard specifications for our IDC cable assembly manufacturing.

Conductor Count

6 to 64 conductors

Pitch Options

1.27mm, 2.0mm, 2.54mm

Cable Types

Flat ribbon, round-to-flat, discrete wire

Connector Brands

3M, Samtec, Amphenol, TE, Hirose, Würth

Voltage Rating

Up to 250V AC/DC

Current Rating

Up to 3A per contact (28 AWG)

Temperature Range

-40°C to +105°C

Cable Lengths

50mm to 3m+ custom lengths

Wire Gauge

28 AWG to 22 AWG

Insulation

PVC, TPE, silicone jacketed

Assembly Styles

IDC Cable Configurations

We build IDC cables in every standard configuration and create custom designs for unique requirements.

Point-to-Point

Standard ribbon cable with identical IDC connectors on both ends. The most common configuration for board-to-board connections within an enclosure.

Daisy Chain

Single ribbon cable with multiple IDC taps along its length. Connects several PCBs or modules in series, common in PLC and industrial control systems.

Breakout Cable

One IDC connector that fans out to individual wires with crimp terminals, ring lugs, or other discrete connectors. Ideal for test fixtures and prototype wiring.

Transition Cable

IDC connector on one end, different connector type on the other — D-Sub, header pins, screw terminals, or custom connector. Bridges between interface standards.

Folded / Stacked

Ribbon cable precisely folded to fit tight enclosures. Rainbow or gray ribbon cable routed through complex chassis layouts with multiple fold points.

Shielded IDC

Ground plane ribbon cable or shielded flat cable with IDC connectors for EMI-sensitive applications. Metal shell IDC housings for improved shielding effectiveness.

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IDC is the fastest path from ribbon cable to finished assembly. When your design calls for 10, 20, or 40+ conductors between boards, mass termination with IDC cuts both cost and lead time compared to crimping each wire individually. The key is choosing the right pitch and locking style for your vibration and density requirements — that's where our engineering team adds real value.

Hommer Zhao

Founder & Cable Assembly Engineer

Custom IDC Cable Assembly Manufacturing for Electronics & Industrial Applications

As a specialized IDC cable assembly manufacturer, OurPCB delivers precision-terminated flat ribbon cables using insulation displacement connector (IDC) technology for electronics, telecom, and industrial control applications. Our cable assembly capabilities cover all standard IDC pitches from 1.27mm high-density to 2.54mm general-purpose configurations, supporting 6 to 64 conductor counts.

IDC mass termination is the most cost-effective method for multi-conductor ribbon cable assemblies. Unlike crimp termination which processes one wire at a time, IDC connects all conductors simultaneously — slashing assembly time and cost while maintaining reliable gas-tight connections. Learn more about the differences in our IDC vs crimp terminals comparison.

We work with leading IDC connector brands including Samtec, Amphenol, TE Connectivity, 3M, and Würth Elektronik. Our connector sourcing network ensures competitive pricing and short lead times even for less common IDC configurations. Combined with our global sourcing capability, we can supply virtually any IDC connector on the market.

For industrial automation customers, our IDC cable assemblies connect PLC I/O modules, relay boards, and HMI panels with precision-folded ribbon cables designed for tight enclosure routing. Telecom applications include patch panel cables, distribution frame wiring, and equipment interconnects using high-density 1.27mm pitch IDC.

Our medical device customers rely on IDC cables for diagnostic instruments and patient monitoring equipment where consistent, repeatable connections are critical. Every assembly undergoes 100% electrical testing including continuity verification, insulation resistance, and visual inspection under magnification.

We also manufacture hybrid cables that combine IDC on one end with D-Sub, FFC/FPC, or discrete wire terminations on the other. This transition cable capability bridges different interface standards within a single assembly, simplifying your bill of materials and reducing assembly steps.

With free DFM review, no minimum order quantity, and ISO 9001 quality systems, we support IDC cable projects from first prototype through volume production. Contact our engineering team or request a quote for your IDC cable assembly requirements.

Common Questions

IDC Cable Assembly FAQ

An IDC (Insulation Displacement Connector) terminates wires without stripping. Sharp metal contacts slice through wire insulation to make electrical contact when pressed together. This enables mass termination — all conductors are connected simultaneously in a single press stroke, making IDC ideal for high-volume flat ribbon cable assemblies.

We support all standard IDC pitches: 2.54mm (0.1 inch) for general electronics, 2.0mm for compact designs, and 1.27mm (0.05 inch) for high-density applications. We stock connectors and cables for the most common configurations and can source specialty pitch sizes for custom requirements.

Yes, we manufacture transition cables that combine IDC on one end with other termination methods on the other — including D-Sub, crimp terminals, solder cups, or board-level connectors. We also build breakout cables that fan out a single ribbon cable to individual wires or connectors.

IDC terminates all conductors at once without wire stripping, making it faster and more cost-effective for multi-conductor ribbon cables. Crimp termination handles one wire at a time but offers higher current capacity and better vibration resistance. We help you choose the right method based on your application requirements. Read our detailed comparison in our IDC vs crimp terminals blog article.

Every IDC cable assembly undergoes 100% pin-to-pin continuity testing and insulation resistance verification. We also perform visual inspection under magnification to verify proper conductor seating. Hi-pot testing, custom functional testing, and environmental testing are available on request.

We have no minimum order quantity. Whether you need 1 prototype for development or 100,000 units for mass production, we deliver the same quality and testing standards. Prototype IDC cable assemblies can ship within 48-72 hours for standard configurations.

Standard IDC connectors are rated for office and light industrial environments. For high-vibration applications, we recommend IDC connectors with integrated locking latches and strain relief. We can also add cable ties, adhesive mounting, or transition to crimp or solder terminations at points subject to mechanical stress.

Need Custom IDC Cable Assemblies?

From single prototypes to mass production runs, we manufacture IDC ribbon cable assemblies with 100% testing and no minimum order quantity.