Custom Cable Assemblies

Trusted Cable Assembly Manufacturer

As an experienced cable assembly manufacturer, Stantek provides contract manufacturing for customer-specific cable assemblies used in demanding OEM and industrial applications. Our controlled production processes focus on consistent assembly, electrical performance, inspection, documentation, and traceability.

Stantek’s cable assembly processes follow ISO 9001:2015 by Smithers Quality Assessments, IPC/WHMA-A-620, and J-STD-001 requirements. Stantek is also DDTC registered and ITAR compliant, supporting regulated applications including defense and aerospace.

Every cable assembly is manufactured according to applicable production requirements and undergoes 100% electrical testing to verify continuity, insulation resistance, circuit integrity, and other specified requirements.

Custom Cable Assembly Manufacturing Capabilities

Stantek provides in-house cable assembly manufacturing capabilities for low-to-mid volume production and customer-specific requirements. Our manufacturing capabilities include:

• Automated wire and cable cutting and processing
• Terminal crimping and connector integration
• Connector assembly and overmolding
• Ultrasonic splicing
• Machine braiding and shielding
• Laser and hot-stamp cable marking
• Heat shrink, potting, and environmental sealing
• Custom Cirris electrical testing
• Inspection, documentation, and production traceability

These cable assembly manufacturing capabilities support consistent production of assemblies with customer-specified dimensions, components, terminations, protection, and testing requirements.

Cable Harness Assembly Configurations for Complex Applications

A cable harness assembly can organize and protect multiple conductors or cables within an equipment or system installation. Depending on the application, cable harness configurations can incorporate multiple conductors, connectors, terminals, shielding, sleeving, strain relief, and other protective components.

Stantek manufactures cable harness assembly configurations according to customer drawings and specifications when the application requires organized routing, multiple connection points, or integrated protective features. The appropriate assembly configuration depends on the electrical, mechanical, environmental, and installation requirements of the finished system.

Why Choose Stantek for Custom Cable Assembly Manufacturing

Stantek combines controlled production processes, quality practices, and flexible low-to-mid volume manufacturing to support customer-specific custom cable assembly manufacturing requirements.

• Application-Specific Configuration: Assemblies can be produced with customer-specified cables, connectors, terminals, shielding, routing, lengths, and protective features.
• Initial Design Support: Stantek provides initial design support and manufacturability feedback to help align approved requirements with practical production.
• Rapid Prototyping: Prototype builds can help customers evaluate configuration, fit, connectivity, and manufacturability before repeat production.
• Flexible Production: Low-to-mid volume capabilities support prototype programs, production runs, and repeat manufacturing requirements.
• Electrical Testing: 100% electrical testing helps verify continuity, insulation resistance, circuit integrity, and applicable requirements.
• Traceability: Production and quality records support documentation, revision control, inspection, and traceability requirements.
• Quality and Compliance: Manufacturing follows applicable quality and industry requirements, including ISO 9001:2015, IPC/WHMA-A-620, and J-STD-001.

How Stantek Supports Cable Harness Manufacturing

Stantek follows a controlled cable harness manufacturing process based on customer drawings, specifications, component requirements, and applicable standards. The process can include:

1. Requirement and Specification Review
   Customer drawings, cable requirements, connector details, termination requirements, and applicable standards are reviewed before production.

2. Material and Component Verification
   Specified cables, connectors, terminals, shielding materials, protective components, and other required materials are verified against production requirements.
3. Cable Preparation
   Cable is measured, cut, stripped, marked, and prepared according to the required assembly specifications.
4. Termination and Assembly
   Terminals and connectors are crimped or assembled as specified. Shielding, sleeving, strain relief, splicing, and other required protective features are incorporated where applicable.
5. Testing and Inspection
   Completed assemblies undergo electrical testing and inspection to verify continuity, insulation resistance, circuit integrity, and applicable assembly requirements.
6. Documentation and Traceability
   Production and quality records are maintained to support consistent manufacturing, inspection, revision control, and traceability.

Stantek as a Custom Cable Assembly Manufacturer

As a custom cable assembly manufacturer, Stantek works with OEM and industrial customers that require assemblies produced to defined drawings, specifications, and application requirements. Our approach supports controlled manufacturing from prototype builds through repeat production.

Stantek can provide initial design support, manufacturability feedback, prototyping, assembly, testing, inspection, and documentation based on the requirements of each program. This helps customers move from approved specifications to consistent production while maintaining required quality and traceability.

From Prototype to Production

Stantek supports custom cable assemblies from initial prototype builds through repeat production. Rapid prototyping can help customers evaluate assembly configuration, fit, connectivity, routing, and manufacturability before moving into production.

Once the configuration and requirements are approved, Stantek can support repeat cable assembly manufacturing using controlled processes, documented requirements, inspection, testing, and traceability. This provides a consistent path from prototype quantities to low-to-mid volume production.

Industries and Applications for Custom Cable Assemblies

Stantek manufactures custom cable assemblies for applications where reliable electrical interconnection, signal transmission, or power distribution is required.

Our assemblies support:

• Defense and Aerospace: Applications requiring controlled manufacturing, traceability, testing, and applicable industry requirements.
• Industrial Automation and Robotics: Power and signal connectivity within automated equipment and robotic systems.
• Automotive and Transportation: Assemblies designed to meet customer requirements for vibration, temperature, routing, and installation.
• Marine: Cable assemblies for demanding environments requiring appropriate protection and reliable connectivity.
• Heavy Equipment and Material Handling: Rugged electrical interconnection for equipment operating under demanding conditions.
• Medical and Electronics: Precision cable assembly applications requiring customer-specified electrical and mechanical configurations.
• Energy and Industrial Equipment: Custom power and signal connectivity for specialized equipment and systems.

Cable Assembly Design Considerations

When developing a custom cable assembly, electrical, mechanical, environmental, and manufacturing requirements should be considered together. Stantek provides initial design support and manufacturability feedback to help align approved customer requirements with practical production.

Important considerations include:

• Voltage, current, and signal requirements
• Cable and conductor requirements
• Connector compatibility
• Termination methods
• Shielding and EMI/RFI protection
• Routing paths and available space
• Cable length and dimensional requirements
• Heat, moisture, chemicals, abrasion, and vibration exposure
• Strain relief and environmental protection
• Applicable industry and regulatory requirements
• Electrical testing and inspection requirements

Custom Cable Assembly Manufacturing for OEM Programs

Stantek serves as a cable assemblies custom manufacturer for OEM programs requiring customer-specific configurations and controlled production.  Each assembly is manufactured according to approved drawings, specifications, component requirements, and application needs.

Our customized cable assembly capabilities allow customers to specify cable construction, connectors, terminations, shielding, protective features, routing, dimensions, and testing requirements. Stantek then supports production through documented manufacturing, inspection, testing, and traceability processes.

Your Partner for Custom Cable Assemblies

When performance, reliability, and production consistency matter, Stantek provides custom cable assemblies manufactured to customer requirements. Our capabilities support initial design support, manufacturability feedback, rapid prototyping, low-to-mid volume production, electrical testing, inspection, and traceability.

Whether you require a prototype or repeat production, Stantek can support your custom cable assembly requirements with controlled manufacturing processes and customer-specific configurations.

Contact Us to discuss your next cable assembly project.