INTERCONNECTS • PCBA-READY • TURNKEY

Custom Cable Assembly Services

From requirements capture to advanced testing, we engineer cable assemblies that protect signal integrity, survive harsh environments, and drop directly into your PCB manufacturing and box-build flow.

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Design → QA

Coverage

100% Continuity

Testing

IPC/WHMA-A-620

Standards

DFM/DFT + 3D routingDesign Support

Waterproof / UV / OilEnvironmental

Continuity • Hi-Pot • TDRTesting

Prototype → Mass ProductionScale

Cable assemblies: The foundation of high-performance interconnectivity

Cable assemblies are essential for ensuring reliable power and data transmission between electronic systems. At APTPCB, we offer high-quality cable assembly services as an integral part of our PCB manufacturing and assembly (PCBA) solutions. Whether for consumer electronics, automotive systems, or industrial machinery, our cable assemblies are designed for efficiency, durability, and top-tier performance.

With APTPCB's PCBA one-stop service, you get a comprehensive solution that simplifies your supply chain, optimizes component sourcing, and ensures the highest standards of quality throughout the production cycle. Let us handle all aspects of your PCB assembly, including custom cable assemblies, to help you deliver reliable and efficient products for your industry.

Foundation of high-performance interconnectivity

Cable assemblies keep power and data moving reliably. As part of our turnkey PCB manufacturing and PCBA services, we design and build assemblies that meet demanding electrical, mechanical, and environmental requirements across consumer, automotive, industrial, and specialty markets.

Working with a single PCBA partner simplifies supply chains, optimizes component sourcing, and ensures consistent quality checkpoints from board fabrication through final box build.

Custom cable assembly: Optimizing your data and power transmission

We provide high-quality custom cable assembly services, designed to meet the most stringent industry standards and application demands. We understand that a high-quality cable is not merely a physical connection, but a core component for ensuring signal integrity and power efficiency. We offer flexible, scalable solutions that perfectly integrate with your overall PCBA and Box Build Assembly processes. Partnering with us, you will benefit from:

Custom cable assembly advantages

High-quality cables are more than connectors—they protect signal integrity and power efficiency. Our integrated workflow delivers engineering coverage, rigorous QA, and cost-optimized production that align perfectly with your PCBAs and system builds.

Core advantages: Why choose our cable assembly services

Choosing us for your custom cable assemblies provides you with multiple key advantages that directly translate into the superior performance, reliability, and market competitiveness of your products.

Signal integrity & durability

Exceptional signal integrity & power efficiency

Precision design

Our engineers focus on impedance matching, crosstalk control, and low attenuation design to ensure lossless transmission of high-speed signals.

Optimized materials

We select high-quality conductors and insulation materials to reduce loss and improve power transmission efficiency, complementing your PCBA performance.

Reduced EMI/RFI

Through effective shielding and grounding designs, electromagnetic interference is minimized, ensuring system stability.

Ultimate durability & environmental adaptability

Robust construction

We select abrasion-resistant, tensile-resistant, and flex-resistant jacket materials and internal structures to extend cable lifespan.

Environmental protection

We offer features such as waterproofing, oil resistance, UV resistance, high/low temperature resistance, and flame retardancy, adapting to various harsh application environments.

Strain relief

Precise strain relief design and overmolding at the connector-cable junction prevent breakage.

Assembly efficiency & integration

Streamlined assembly process & cost optimization

Plug-and-play

Pre-fabricated and tested cable assemblies significantly simplify the final product assembly, reducing labor and time costs.

Reduced errors

Standardized production and rigorous testing ensure consistent quality of cable assemblies, lowering assembly error rates and rework needs, accelerating your PCBA final assembly.

Reduced inventory complexity

Through customized integration, the management burden of multiple loose wires and connectors is reduced.

High integration & space optimization

Custom lengths & configurations

We provide precise cable lengths, branching, and connector configurations based on your specific product dimensions and layout, avoiding redundancy and waste.

Compact design

Utilizing small-diameter, flat, or hybrid cable designs maximizes the use of limited space, supporting product miniaturization.

Seamless PCBA integration

Our cable assemblies perfectly match your PCB design and PCBA on-board connectors, ensuring seamless electrical and mechanical integration.

Quality assurance & customization

Assured quality consistency & full compliance

Standardized production

We adhere to strict manufacturing standards and processes (e.g., IPC/WHMA-A-620) to ensure consistency across all cable assembly batches.

Comprehensive testing

Every cable assembly undergoes multiple rigorous tests to ensure electrical performance and mechanical integrity.

Certification support

UL, CE, RoHS, and other international certification support can be provided as needed, meeting global market access requirements.

Flexible customization & engineering support

Material & structure customization

We offer a variety of conductor, insulation, shielding, and jacket material options, as well as customized internal structures (e.g., number of twisted pairs, fillers).

Connector customization

Standard or custom connectors can be provided based on the application, including special pin arrangements, latches, or locking mechanisms.

Prototyping to mass production

We provide professional support throughout the entire process, from engineering consultation in the product concept phase and prototype fabrication to final mass production.

Our cable assembly design & pre-production process

Designing high-quality cable assemblies requires a deep understanding of electrical, mechanical, and material sciences. We follow a rigorous design and pre-production process, ensuring the final product precisely meets your technical specifications and performance expectations, and seamlessly integrates with your PCB design and PCBA manufacturing.

Five-step cable design & pre-production workflow

1
Detailed requirements analysis & definition
Clearly define electrical parameters (signal type, voltage, current, frequency, impedance, bandwidth), mechanical & environmental requirements (length, bending radius, temperature range, waterproof rating), connector interfaces, and compliance standards (UL, CSA, CE, IPC/WHMA-A-620).
2
Cable structure & connector selection
Select appropriate conductor materials (bare copper, tinned copper), insulation materials (PVC, PE, XLPE, PTFE), shielding design (braid, foil, copper tape), outer jacket materials (PVC, PUR, TPE), and connectors & terminals that meet all requirements.
3
3D modeling, simulation & routing optimization
Utilize advanced 3D CAD software for detailed modeling, conduct Signal Integrity (SI), Power Integrity (PI), and EMI simulations, perform mechanical analysis for bending/tension/vibration, and validate cable routing paths within the overall product 3D model.
4
Prototype fabrication & comprehensive validation
Fabricate cable assembly prototypes, conduct electrical performance testing (continuity, insulation resistance, impedance, attenuation, crosstalk), perform mechanical performance testing (tensile strength, flex life, vibration, temperature shock), and conduct PCBA compatibility testing with actual PCBAs.
5
Documentation generation & version control
Generate detailed engineering drawings with all dimensions and materials, output complete Bill of Materials, provide detailed test reports and compliance certification documents, and strictly manage design changes and version iterations for production traceability.

Our advanced cable assembly manufacturing process

Cable assembly manufacturing is a highly specialized, precise, and detail-oriented process. We employ advanced equipment and strict production processes to ensure every cable assembly meets the highest standards of quality and reliability, complementing our PCBA manufacturing capabilities.

Six-step advanced cable manufacturing process

1
Precision wire processing
High-precision automatic cutting machines cut wires to exact lengths, automatic equipment precisely strips outer jacket and conductor insulation, multi-strand wires are twisted or pre-treated (such as tinning) to improve solderability and connection reliability.
2
Connector termination process
High-precision crimping machines accurately crimp terminals onto wires with regular pull-force testing, IPC-certified professional solderers perform fine soldering for connectors requiring soldering, specialized connector assembly tools and fixtures ensure correct contact insertion and precise connector assembly.
3
Cable body assembly & forming
Inner core wires are twisted, shielded, filled, or wrapped according to design requirements to form the cable's core structure, cable's outer jacket is formed by extrusion or wrapping according to design requirements, cable branching or fan-out processing is performed for complex application needs.
4
Protective layers & strain relief
Braids, foils, or other shielding layers are accurately applied to provide excellent EMI/RFI protection, protective tubing, braided sleeving, corrugated tubing, or tape wrapping is installed to enhance abrasion resistance and environmental protection, precision overmolding at the connector-cable junction provides excellent strain relief and waterproofing/dustproofing.
5
Labeling & identification systems
Laser engraving, heat-shrink labels, adhesive labels, or color codes are applied to clearly mark cable model, length, batch, and function, every cable assembly has complete traceability, facilitating quality management and after-sales service.
6
Rigorous quality control & integrated testing
100% continuity testing verifies electrical continuity, opens, shorts, and miswires; insulation resistance testing measures insulation reliability; dielectric withstanding voltage (hi-pot) testing verifies insulation under high voltage; impedance, attenuation, crosstalk testing ensures signal integrity; pull force testing verifies mechanical strength; flex life testing evaluates flexibility and fatigue life; environmental testing simulates actual use conditions; functional testing ensures compatibility with PCBAs or actual devices.

Integrated testing & QA

Electrical coverage

100% continuity

Automated equipment verifies opens, shorts, and miswires across every conductor.

Insulation & hi-pot

Resistance and dielectric withstand testing ensure insulation reliability under stress.

High-speed validation

TDR, attenuation, and crosstalk testing confirm SI performance for data/RF cables.

Mechanical & environmental

Mechanical robustness

Pull-force sampling, flex-life cycling, vibration, and tensile tests verify durability.

Environmental stress

High/low temperature, humidity, and chemical resistance tests simulate real-world use.

Functional checks

System-level tests with actual PCBAs ensure seamless electrical and mechanical integration.

Choose us for your custom cable assembly needs

When your products demand exceptional quality, performance, and reliability from cable assemblies, we are your ideal integrated manufacturing partner. With deep experience in PCB Manufacturing, PCBA Assembly, and sophisticated interconnect solutions, we are dedicated to excellence throughout your entire electronic product lifecycle.

By choosing us, you will ensure your custom cable assembly needs are met with:

Why choose APTPCB for cable assembly

•Expert engineering design: Providing tailored solutions from concept to reality, built upon our extensive PCBA design expertise.
•Advanced manufacturing capabilities: State-of-the-art equipment and processes, aligned with our high standards for PCB fabrication.
•Rigorous quality control: Comprehensive testing and inspection procedures, integrated with our PCBA testing protocols, ensuring perfect performance.
•Cross-industry experience: Proven expertise in the most demanding sectors, including telecommunications, consumer electronics, industrial automation, medical, and automotive.
•Competitive pricing: Cost-effective solutions without compromising the critical quality or reliability of your cables.
•Responsive customer support: A dedicated team committed to assisting you throughout the project lifecycle, from initial PCB prototyping to final product delivery.

Partner with us for superior interconnectivity

Partner with us to achieve superior electrical connectivity, enhanced reliability, and streamlined production for your next-generation electronic products.

Need custom cable assemblies for your next build?

Share drawings, BOMs, routing paths, and compliance targets—we’ll return coverage plans, prototype schedules, and production quotes within one business day.