Custom Cable Assemblies

Quality Assurance and Compliance

Quality requirements are an important part of cable assembly manufacturing, particularly when assemblies must meet defined electrical performance, workmanship, documentation, or regulatory requirements.

Stantek maintains an ISO 9001:2015 by Smithers Quality Assessments. View Certificate quality management system and applies inspection and verification procedures according to applicable product specifications and customer acceptance criteria.

Depending on the project, relevant workmanship requirements may include IPC/WHMA-A-620 for cable and wire harness assemblies. J-STD-001 may apply where soldered electrical assemblies are involved. Applicability depends on the product and contract; these standards should not be interpreted as automatic certification of every assembly.

Stantek also maintains DDTC registration and ITAR compliance for applicable defense-related work. Customers should identify any program-specific regulatory, documentation, handling, or traceability requirements when requesting a quotation.

Custom Cable Assembly Manufacturing Capabilities

Stantek provides production capabilities for preparing, terminating, assembling, identifying, and finishing custom cable assemblies. The processes selected for each project depend on the cable construction, specified components, assembly configuration, and acceptance criteria.

Our capabilities may include:

• Wire and Cable Processing: Cutting and preparation to specified lengths and production requirements.
• Terminal and Connector Application: Crimping and connector termination according to assembly specifications.
• Wire Identification and Marking: Printing or marking to support identification and assembly requirements.
• Cable Joining: Applicable joining processes, including ultrasonic splicing where suitable for the materials and configuration.
• Braiding and Shielding: Shielding or braiding operations for supported cable configurations.
• Protection and Finishing: Specified heat shrink, overmolding, potting, or sealing methods where required and available for the project.

Not every process applies to every product. The production approach is established according to the specific project requirements and the processes supported for that configuration.

Cable Assembly Testing and Quality Verification

Testing helps verify that a cable assembly meets its defined electrical and workmanship requirements. The appropriate verification methods depend on the assembly specifications, intended application, and agreed acceptance criteria.

Depending on the project and available testing capabilities, verification may include:

• Continuity Testing: Checking specified electrical paths for continuity.
• Open-Circuit and Short-Circuit Checks: Identifying unintended interruptions or electrical connections between circuits.
• Workmanship Inspection: Checking assembly construction, terminations, component placement, and other specified acceptance criteria.
• Additional Specified Electrical Tests: Performing other tests when required by the assembly specification and supported by the applicable test equipment.

Stantek determines the applicable inspection and testing requirements according to the project documentation and agreed quality criteria. Customers should identify any required test limits, acceptance criteria, records, or reports when submitting a quotation request.

Benefits of Working with Stantek

Selecting a cable assembly manufacturer involves more than finding a supplier that can connect wires and terminals. Buyers also need a clear understanding of specifications, production requirements, quality expectations, and order planning.

Stantek supports suitable customer programs through:

• Build-to-Print Production: Assemblies manufactured to customer-provided drawings, bills of materials, and specifications.
• Initial Design Consultation: Discussions and manufacturability feedback to help clarify requirements before production.
• Low-to-Mid-Volume Manufacturing: Production support for suitable quantities, including initial builds and recurring orders.
• Production Coordination: Communication about component requirements, order quantities, lead times, and project planning.
• Defined Inspection Requirements: Verification based on applicable drawings, specifications, and agreed acceptance criteria.
• U.S.-Based Manufacturing: Production at Stantek’s facility in Stanton, Kentucky.

Our Cable Assembly Production Process

The cable assembly manufacturing process follows the requirements documented for each project. The exact sequence and operations vary according to the assembly configuration and customer specifications.

1. Requirement Review: Stantek reviews available drawings, specifications, quantities, application requirements, and acceptance criteria to understand the requested assembly.
2. Material and Component Verification: The specified cable, connectors, terminals, and other required components are reviewed against the project documentation.
3. Cable Preparation: Cable is cut, stripped, marked, or otherwise prepared according to the documented requirements.
4. Termination and Assembly: Terminals and connectors are applied, specified joining operations are completed, and the components are assembled into the required configuration.
5. Inspection and Verification: The assembly is checked against applicable specifications and agreed acceptance criteria.
6. Documentation and Order Preparation: Required records are completed, and conforming assemblies are prepared for shipment according to the agreed order requirements.

The exact production sequence depends on the assembly configuration and the requirements agreed for the order.

Industries and Applications for Cable Assemblies

Custom cable assemblies provide electrical connections for power distribution, signal transmission, communication, and control systems. Stantek manufactures cable assemblies to customer specifications for OEM equipment and applications that require defined cable configurations, connectors, terminations, and routing.

• Aerospace
  Aerospace applications may use cable assemblies in aircraft support equipment, avionics-related systems, and specialized electronic equipment. Assemblies can be configured with specified cables, connectors, shielding, and terminations to suit the application. Manufacturing follows customer drawings, component specifications, and applicable program requirements.

• Defense

  Defense equipment uses cable assemblies to connect power sources, communication systems, electronic equipment, and control components. Depending on the application, assemblies may require specified connectors, shielding, protective features, and documented manufacturing controls. Stantek manufactures assemblies according to customer specifications and applicable program requirements.

• Technology

  Technology products use cable assemblies to connect electronic devices, communication equipment, networking systems, and control components. These assemblies may support power delivery or signal and data transmission, depending on the application. Cable type, connector configuration, shielding, and assembly dimensions are selected according to customer specifications.

• Medical

  Medical and diagnostic equipment may use cable assemblies to connect instruments, electronic modules, monitoring equipment, and other electrical components. Assemblies are configured to meet the equipment’s specified electrical, connector, routing, and material requirements. Manufacturing and verification requirements depend on the customer’s specifications and intended application.

• Automotive

  Automotive and transportation equipment uses cable assemblies for power, signal, lighting, instrumentation, and electronic control connections. Assemblies may include application-specific cable lengths, terminals, connectors, protective sleeving, and routing configurations. Stantek manufactures these assemblies according to customer drawings and specified operating requirements.

• Marine

  Marine equipment may use cable assemblies to connect onboard electrical equipment, communication systems, instrumentation, and power distribution components. Depending on the operating environment, specifications may define requirements for insulation, connectors, shielding, routing, and environmental protection. Each assembly is manufactured according to the application’s electrical and environmental requirements.

• Robotics & Automation

  Robotics and automation systems use cable assemblies to connect controllers, sensors, actuators, motors, and other electrical components. Assemblies may be configured for defined routing paths, signal transmission, power delivery, and equipment movement where specified. Stantek manufactures cable assemblies according to customer requirements for automated machinery and industrial systems.

The required cable construction, conductor size, connector type, shielding, termination method, routing, and verification criteria vary by application. Stantek reviews customer drawings and specifications to evaluate manufacturing requirements and prepare quotations.

From Prototype to Production

Stantek supports suitable prototype, quick-turn, and low-to-mid-volume programs. Moving from an initial build to recurring production depends on specification readiness, component availability, testing requirements, and the agreed project schedule.

For an initial review, share the documentation available for your project, including drawings, component information, estimated quantity, and required delivery date. If a drawing or specification needs clarification, Stantek can discuss the requirements and provide initial design consultation or manufacturability feedback.

What to Include in Your Cable Assembly Specifications

Clear specifications help a custom cable assembly manufacturer assess a project, understand the required configuration, and prepare an accurate quotation. Include as many of the following details as are available.

• Drawings and Documentation: Current drawings, revision levels, wiring diagrams, and bills of materials.
• Cable Requirements: Cable type, conductor size, length, insulation, shielding, and color identification.
• Connectors and Terminals: Part numbers, termination details, and required connection arrangements.
• Operating Conditions: Applicable temperature, moisture, vibration, chemical exposure, or other environmental requirements.
• Electrical Requirements: Voltage, current, signal characteristics, continuity, insulation resistance, or other specified test criteria, as applicable.
• Quantity and Schedule: Prototype quantity, initial order volume, expected recurring demand, and requested delivery date.
• Quality and Compliance: Inspection criteria, documentation, traceability, and applicable industry or program requirements.

Not every project requires every item. If some information is not yet available, share your existing documentation so the outstanding requirements can be identified during the initial review.

Request a Quote for Custom Cable Assemblies

Need custom cable assemblies built to your specifications? Contact Stantek to discuss your requirements and request a quote.

Share your available drawings, bill of materials, cable types, connector configurations, required quantities, and target schedule. Our team will review the information provided and identify any additional details needed to evaluate your project. Whether you require prototype assemblies or low-to-mid-volume production, Stantek can assess your requirements based on your specifications. Get in touch to discuss your custom cable assembly needs.