Custom Cable Assembly

Custom cable assembly — micro coaxial, 36–50 AWG, 1–512 cores. Prototype (5 pcs) in 3–5 weeks, production (50+). Any connector, jacket, or phase match. ISO 9001. OEM since 2003.

Ultra-Fine Gauge × Ultra-High Core Density

ePTFE Low-Loss Dielectric Technology

Dual-Layer Shielding — Channel Isolation >40 dB

High-Flex — 1M Flex / 5M Torsion Cycles

ISO 9001 Certified · Fast Turnaround · Full Customization

Phase Matching ±1% — 100% TDR Verified

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Custom Cable Assembly

Products

Specialty Cable Assemblies

Every cable assembly we manufacture is custom — built to your specification for your application. We do not sell catalog cables from a distributor shelf. Whether you need 5 prototype assemblies for a new IVUS catheter or 10,000 per month for an established ultrasound probe line, the process starts with your specification and ends with a 100% tested, fully documented cable assembly.

Custom Cable Assembly is our core business: 36–50 AWG micro coaxial, 1 to 512 cores, any connector interface, any jacket material, phase-matched or unmatched, single-ended or hybrid. ISO 9001:2015 certified. OEM manufacturer since 2003.

What We Customize

Parameter	Range
AWG gauge	36, 38, 40, 42, 44, 46, 48, 50
Core count	1 (single cable) to 512 (bundled assembly)
Impedance	50 Ω (standard), 75 Ω, or 100 Ω differential (twinax)
Phase matching	Unmatched, ±1.0%, ±0.5%, custom tolerance
Cable format	Round bundle, ribbon, hybrid composite
Dielectric	ePTFE, FEP, PTFE
Conductor construction	Solid, 7-strand, 19-strand rope-lay
Jacket material	PVC, PUR, PFA, FEP, PE, silicone, PTFE
Connector (proximal)	I-PEX, HIROSE, LEMO, BNC, SMA, Microdot, custom
Connector (distal)	Solder pads, wire bond, crimp, custom overmold
Cable length	50 mm to 5+ meters, ±5 mm tolerance
Shielding	Standard (foil + single braid), double braid, segmented
Biocompatibility	ISO 10993-5, 10993-10, 10993-11
Sterilization	Autoclave, EtO, gamma, H2O2 plasma compatible
Special	Non-ferromagnetic (MRI), counter-helical (torsion), IP68

Process — From RFQ to Production

Step 1: Submit RFQ (Day 0)
Share your cable specification, drawing, or application description. Include: AWG, core count, connector type, cable length, jacket material, phase-match requirement, annual volume estimate. Use our RFQ template (downloadable) or free-form email.

Step 2: Engineering Review & Quote (Day 1–2)
Our application engineer reviews your specification for manufacturability. You receive: formal quotation (prototype and production pricing), DFM feedback (if any design modifications are recommended), and confirmed delivery timeline. 48-hour turnaround for standard configurations; 3–5 business days for complex hybrid or novel constructions.

Step 3: Design Confirmation (Day 3–5)
For complex assemblies: we provide a cable cross-section drawing showing element arrangement, dimensions, and material callouts. You approve before prototype production begins. For standard configurations: proceed directly to prototype.

Step 4: Prototype Manufacture (Weeks 2–5)
5–10 prototype assemblies produced on production-representative tooling and processes. Every assembly receives 100% electrical testing. Shipped with: FAIR (First Article Inspection Report), per-channel TDR certificate (phase-matched), 100% test records, material certificates.

Step 5: Qualification at Your Facility (Weeks 5–8)
Install prototypes in your device. Run your standard incoming inspection and functional verification. If modifications are needed, we iterate — typically 1 additional prototype round (2–3 weeks).

Step 6: Production (Ongoing)
After qualification, place repeat production orders. Pricing locked for 12 months per quote. MOQ: 50 assemblies. Delivery: 2–5 weeks depending on complexity and volume.

Pricing Structure

Order Type	Quantity	Lead Time	Pricing Notes
Prototype	5–10 pcs	3–5 weeks	Prototype pricing (1.5–2× prod)
First production	50–100 pcs	3–5 weeks	Production pricing
Repeat production	50–500 pcs	2–4 weeks	Volume discount at 100+ pcs
High volume	500–10,000+ pcs/mo	2–3 weeks	Best per-unit pricing
Standing order program	Monthly scheduled	2–3 weeks	Locked pricing + priority slot
Emergency / expedited	Any quantity	1–3 weeks	+15–25% surcharge

Tooling: No tooling charges for standard connector terminations. Custom overmold tooling: one-time charge, typically $2,000–$5,000, amortized over production volume. Tooling ownership: customer retains ownership.

Quality System and Documentation

ISO 9001:2015 certified. Every cable assembly ships with documentation tailored to your quality system requirements:

Standard documentation (included):
- Certificate of Conformance (CoC) per lot
- 100% Electrical Test Records per serial number (continuity, TDR impedance, HiPot, insulation resistance)
- RoHS/REACH Declaration of Conformity

Phase-matched assemblies (additional):
- Per-channel TDR Phase-Match Certificate

Medical device customers (available on request):
- First Article Inspection Report (FAIR)
- ISO 10993 Biocompatibility Declarations
- Material Certificates with lot traceability
- IQ/OQ/PQ documentation support
- PPAP (Production Part Approval Process) Level 3

Supply chain customers:
- Conflict Minerals Declaration
- CMRT (Conflict Minerals Reporting Template)
- Supplier Quality Agreement template

Industries Served

Medical Devices: Ultrasound probes, endoscopes, catheters, surgical robots, MRI/CT/PET imaging, patient monitoring. Our largest market — approximately 65% of production volume.

Industrial NDT: Phased-array bundles, TOFD pairs, contact probe cables, pipeline inspection. Second largest market — approximately 20% of volume.

Research & Development: University labs, corporate R&D, prototype instruments. Low-volume custom configurations with fast turnaround.

Defense & Aerospace: Specialized sensor cables, non-standard configurations, extended documentation requirements.

Consumer Electronics: Display cables, camera modules, high-speed internal interconnects for premium devices. High-volume production capability.

Frequently Asked Questions

What is the minimum order quantity?

Prototype: 5 assemblies. Production: 50 assemblies per order. Bulk cable reel: 500 m. We do not have a minimum annual volume commitment requirement.

Can you work from a verbal description rather than a formal drawing?

Yes — especially for early-stage projects. Describe your application: what signals, what connector, what size constraint, what environment. Our engineer will propose a cable construction and provide a specification drawing for your approval before manufacturing.

Do you sign NDAs?

Yes. Mutual NDA standard before any proprietary specification exchange. We maintain strict confidentiality of customer designs and do not cross-sell specifications between customers.

Can you source and stock connectors for us?

Yes. We maintain inventory of common I-PEX, HIROSE, LEMO, BNC, and Microdot connectors. For customer-specific or OEM-proprietary connectors, we can establish consignment stock at our facility for fast production turnaround.

What happens if the prototype does not pass our qualification?

We analyze the failure mode (electrical, mechanical, dimensional) and propose a design modification. Second-round prototypes are produced at reduced cost (material + labor only, no engineering re-charge) with expedited lead time (2–3 weeks). In 4+ years, our first-pass qualification rate exceeds 97%.

Do you offer design services for new cable specifications?

Yes. For Applications where you know the functional requirements (signal types, environment, form factor) but do not have a cable specification, our application engineering team designs the cable construction. Design service is free for projects proceeding to prototype order; standalone design consultation is quoted hourly.

Have a cable specification or application requirement? Submit your RFQ — engineering quote within 48 hours.

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Applications

Ultrasound Probe & Transducer

Modern 3D ultrasound probes contain 128–512 piezoelectric elements requiring precisely matched electrical path lengths for accurate beamforming. Multi-core micro coaxial cable provides per-channel shielding with phase-matched construction, serving as the core interconnect for GE, Philips, Siemens, and Mindray platforms.

Medical Endoscope Camera

Endoscope insertion tubes of 2–4 mm diameter must transmit HD/4K video while enduring 1M+ flex cycles. Using 42–46 AWG stranded conductors, OD achieves as small as 1.2 mm, supporting HD-SDI and 4K LVDS signals while meeting ISO 10993 biocompatibility requirements.

Robotic Surgery Cable

Robotic surgery arms must carry imaging signals, electrosurgical RF power, motor drive currents, and fiber optic illumination through ±270° articulating joints — all within a single hybrid assembly. Micro coaxial elements serve as the signal core, qualified to 5 million torsional flex cycles.

NDT Ultrasonic Testing (PAUT / TOFD)

Weld inspection and corrosion mapping in petrochemical, nuclear, and aerospace industries use PAUT and TOFD — requiring 16–256 core, phase-matched ±1%, 50 Ω micro coaxial bundles with industrial PUR/FEP/PTFE jackets, compliant with ASME V and EN 583-2 standards.

MRI-Compatible Device Cables

The MRI bore presents three electromagnetic environments requiring all metals to pass ASTM F2503 ferromagnetic assessment. Non-magnetic silver-plated copper alloy conductors meet 1.5T/3T MRI safety requirements for MRI-guided interventions, coil connections, and CT detector array interconnects.

Semiconductor / Industrial Robotics / Aerospace

Semiconductor wafer AOI inspection, industrial robot joint routing, and aerospace sensor arrays all demand high-density, fine-gauge cables with tight impedance control and signal integrity — areas where micro coaxial cable delivers unmatched performance in high-frequency transmission, channel isolation, and compact construction.