Cable Assembly Processing Capabilities

Epec supports a wide variety of custom cable assemblies that range in technology and complexity from low voltage hook up wires to overmolded breakout assemblies, as well as RG316 coaxial cable assemblies. Whether it is taking an existing industry standard like USB and modifying it, or if it’s a completely new design, our customized cable assemblies provide solutions for all market sectors.

Epec services our customers and helps them achieve their goals through an integrated system of services that will foster a strong and collaborative relationship. We use the highest quality materials, components, and workmanship to design, develop, and manufacture cable assemblies. Built using ISO approved manufacturing processes, our automated wire preparation and assembly systems empower us to supply both your prototype runs and full rate production requirements in a timely manner.

In addition, each new cable design undergoes a complete design for manufacturability review offering opportunities to reduce supply chain risk, improve reliability, or save money. Upon program launch, an integrated product team that consists of customer service, manufacturing, engineering, logistics, and quality will verify that all specifications and program objectives are addressed keeping you the customer informed and up to date.

Epec follows IPC/WHMA-A-620 for all cable assembly, test and inspection practices for all applicable design applications.

Our Cable Assembly Processing Capabilities Include:

Connector, Terminals, and Crimp Options

Consider a wire to board connector for a quick solution to terminate your cable to a PCBA. See our blog post on Using Wire-To-Board PCB-Mounted Connectors In Your Cable Assembly for more information.

Wire Preparation and Automation

• Hard wired
• Flying leads with variable lengths
• Tinned
• Stripped and tinned
• Cut leads
• Precise cut lengths
• Strip and tin tolerances of +/- 1mm or better
• Ultrasonic weld preparation
• Jacket scoring
• Heat shrink jacketing
• Tie and lacing
• Custom wrapped tapes and foils
• Conduit
• Extruded tubing

As complexity increases on wire harnesses, some of the benefits of automation can be impacted. Where possible, decreasing the complexity of your cable may have exponential cost and lead time benefits through automation. See our blog pots titled Why Complex Wire Harnesses Cannot Be Fully Automated for more information.

Ruggedization and Customization

• Molded members
• Injection molded components
• Mating housings
• Overmolded strain relief
• Overmolded PCBA assemblies
• Customized RTV potting
• Epoxy encapsulation and potting
• Sleeving and wraps
• Nylon braiding
• Shielded and conductive overbraids
• Barcode
• Four color ink stamping
• Circuit Identification
• Heat shrink labels

If you are considering a custom overmolded design, Managing The Development Of Your Overmolded Cable webinar covers several design tips to reduce risk and cost of your project.

Shielding

• Braided wire
• Overbraiding
• EMI/RFI shielding
• Polyester/aluminum foil
• Polyester/aluminum foil and braid spiral serve wire
• Foil tapes and wraps
• Copper tape with adhesive
• Mil-Spec certified and tested

Since shielding can add cost, weight, or complexity to your cable, and not all shielding is the same, it’s best to review options before moving forward. Read more in our blog post on an overview of cable shielding options for your project.

Adding Components and Sub-Assemblies to Your Wire Harness

• HDMI/Display Port/Mini Display Port
• USB, USB-A, USB-B, MicroUSB, USB MINI
• LEDs and other lighting options
• Fan assemblies
• Battery terminals
• PCBAs
• PCBA housings and enclosures
• Normally open switches
• Normally closed switches
• Grommets and elastomeric boots
• Embedded systems and microcontrollers
• Custom machined members
• Sheet metal and formed members

It is easy to aim for the stars and try to build the perfect solution, especially on your first shot. But sometimes there are simple steps that can be taken to dramatically ease the burden on Engineers. Using an existing and proven design with slight customization can be the difference in your project.

Material Additives

• Rodent resistant
• Anti-microbial
• Anti-fungal compounds
• Improved hydrophobicity

Adding rodent repellents to your custom cable extrusion helps address a very unique requirement to mitigate the risk damage and open circuits from pests.

Connector Options and Partners

• Molex
• Amphenol
• Glenair
• TE/AMP
• JST
• Hirose
• Samtec
• Nicomatic
• Canon
• Souriau
• As well as many other producers

Epec supports all major connector and component manufacturers. Epec offers a complete portfolio of form, fit, and function replacement parts as drop in substitute components that can help reduce cost and lead time in your project. See our 5 tips when substituting connectors for your custom cable assembly blog post for more information.

Insulation/Jacket Materials

• PVC - Polyvinyl Chloride
• IRR/PVC - Irradiated Polyvinyl Chloride
• XLPE - Cross-Linked Polyethylene
• Vinyl (PVC)
• Silicone Jacketed
• Customized Silicone Extrusions
• SR-PVC - Semi Rigid Polyvinyl Chloride
• Cellular Polyethylene
• EPDM - Ethylene Propylene Diene Monomer
• TPE/TPR - Thermoplastic Elastomers
• PE - Polyethylene
• LDPE - Low Density Polyethylene
• HDPE - High Density Polyethylene
• Cellular (Foam) Polyethylene
• PU - Polyurethane
• Polyurethane/Nylon
• Low Smoke Plenum Co-Polymers/PVC
• PP - Polypropylene
• Cellular (Foam) Polypropylene
• FEP - Fluorinated Ethylene Propylene
• TFE - Tetrafluoroethylene
• PTFE - Polytetrafluoroethylene
• ETFE Tefzel
• PVDF Kynar
• ECTFE Halar

Where possible, selecting readily available wire with standard jacket options helps get a proof of concept moving forward. See our blog post for tips for using common UL wire to get to market faster.

---

Conductor Options, Materials, and Coatings

Epec offers 'that range from standard and low-cost tinned copper wire, to mil-spec silver plated conductor options.

Conductor Cross Section Options

• 4AWG to 40 AWG
• 1 Conductor to 60+ legged multiconductor cables
• LVDS and twisted pairs
• Coaxial cables
• -65C to +250C temperature ratings

Voltage Rating Options

• 30V
• 300V
• 600V
• 1500V
• 3000V

Conductor Options

• Bare copper wire
• Tinned copper wire
• Heavy tinner copper wire
• Silver plated copper wire
• Nickel plated copper wire
• Copperweld/copper covered steel
• Specialty conductor coatings including:
  • Prefused copper
  • Overcoat copper
  • Top coated copper
• Stranding constructions
  • Solid
  • Bunched
  • True concentric
  • Rope lay

See our blog post for more information about our Cable Assembly Conductor Options.

Testing

• Approvals
  • UL, CSA, and industry testing procedures
• Standard electrical tests
  • Continuity and resistance measurements
  • HIPOT/dielectric testing
  • Insertion loss/VSWR
  • Automated low voltage test stations
• Temperature and environmental testing
  • In house ESS chamber
  • In house thermal chambers capable of operational testing from -50C to +80C
  • Complete
• EMI / EMC testing
  • Radiated emissions
  • Radiated susceptibility
  • Conducted emissions
  • Conducted susceptibility
  • ESD/air discharge test
• IP Waterproof and pressure testing
  • Leak testing using positive pressure fixtures
  • Submersion tests to identify leak paths
• Custom wire harness test fixtures
  • Custom pogo pin fixtures
  • Automated test stands
  • Customer supplied test equipment
• Custom testing options are available upon request

See our blog post for more information on exploring test options for your customer cable assembly.

---

Optimize Your Project with Tailored Cable Solutions

Tap into Epec's expertise and ISO-certified processes for custom cable assemblies designed to meet your exact needs.

Request a Quote   Request Design Support   Request More Information