Cable Assembly Manufacturing Capabilities

Epec provides custom cable assembly manufacturing services for power, data, and signal applications, supporting everything from design and prototyping to production and inventory management. Capabilities range from low-volume, high-mix programs to high-volume manufacturing, with solutions spanning wire harnesses, overmolded cables, ribbon cables, shielded assemblies, coaxial cables, and industry-specific cable systems. Engineering support focuses on delivering the most appropriate balance of performance, manufacturability, and cost.

At a Glance: Manufacturing Capabilities

• End-to-end cable assembly support: Epec provides custom cable assembly solutions from design and prototyping through production and inventory management, supporting both low-volume and high-volume manufacturing programs.
• Broad manufacturing capabilities: Capabilities include wire harnesses, overmolded cables, ribbon cables, shielded cable assemblies, power cables, coaxial cable assemblies, and industry-specific solutions for automotive, medical, and military applications.
• Engineering-focused design optimization: Using design, prototyping, and global manufacturing resources, Epec helps customers develop cable assemblies that balance performance, manufacturability, and cost for power, data, and signal applications.

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End-to-End Custom Cable Assembly Manufacturing

Epec Engineered Technologies offers a broad range of custom cable assembly solutions for power and data applications. Our engineering and manufacturing expertise allows our team to support cable designs from initial concept through full production while helping customers identify the lowest-cost and highest-performing solution for their application.

Services include:

• Design and development
• Rapid prototyping
• Production manufacturing
• Inventory management
• Global manufacturing support

Using SOLIDWORKS for cable design, Epec can work from STP files to produce 3D-printed prototypes for early fit verification and design validation. After the design is finalized, production transitions to full-rate manufacturing facilities with ongoing inventory management throughout the life of the project.

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Custom Cable Assembly Production Capabilities

Epec’s manufacturing capabilities cover a wide variety of cable and wire harness technologies used in consumer electronics, industrial equipment, medical devices, and other electronic products.

Our vertically integrated approach allows design, prototyping, production, and lifecycle support to be managed within a single program structure, all while incorporating truly custom solutions.

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Low Voltage Hook-Up Wire Harnesses

For applications requiring 300 VDC or less, Epec supports numerous UL-specified and industry-standard wire harness constructions.

Capabilities include:

• Discrete wire assemblies
• Multiconductor wire harnesses
• Configurations from 1 to more than 100 conductors
• Internal wiring systems for consumer products
• Industrial machine harnesses
• Medical device wire harnesses
• General electronic equipment harnesses

These wire harnesses are commonly used where reliable internal power or signal distribution is required.

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Data and Video Cable Assemblies

Epec supports a wide range of standard data and video cable configurations, including:

• D-Sub
• USB
• HDMI
• DisplayPort
• RCA
• RJ45
• RJ11

Supported configurations include male and female connector styles, standard and micro form factors, and USB Type A, Type B, and Type C connector designs.

To increase ruggedness and improve durability, these cable assemblies can be produced with overmolded connectors and integrated strain relief features.

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Custom Overmolded Cables

Overmolding helps protect the electrical connections and sensitive components located within cable assemblies. In addition to environmental and mechanical protection, overmolds can be used to incorporate customized features such as artwork, handles, and encapsulated PCB assemblies.

Overmold materials are selected to bond with the parent cable jacket material, creating a ruggedized and sealed strain relief that protects internal electronics.

Benefits of Overmolding

• Protects electrical connections
• Supports waterproof cable designs
• Improves connector durability
• Adds strain relief
• Enables custom mechanical features
• Allows encapsulation of PCB assemblies

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Flat Flexible Cables and Ribbon Cables

Flat flexible cables and ribbon cables are constructed from parallel conductors bonded together in a flat arrangement. Conductor spacing and wire size can be tailored to application requirements.

Typical capabilities include:

• Constructions from 2 to more than 60 conductors
• Industry-standard cross sections and materials
• Custom colors and extrusions
• Standard ribbon cable configurations for IDC connections
• Polyester, Polyimide, and PVC

One commonly used configuration is a 0.050-inch pitch, 28 AWG, UL-approved ribbon cable available in a wide range of conductor counts. These assemblies are typically gray with a stripe identifying Pin 1.

Common Ribbon Cable Specifications

Parameter	Value	Units
Conductor count	2 to 60+	conductors
Common ribbon cable pitch	0.050	inch
Common wire size	28	AWG

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Shielded Cable Assemblies

Most cable assemblies incorporate some form of shielding. Shielding may provide physical protection through armored constructions, but it is more commonly used to preserve signal integrity and contain electromagnetic emissions.

Shielded cable designs may utilize conductive foil layers, braided shielding, or other electrically conductive wraps or films. Data cables that are designed to operate within electric fields may contain both a metallized foil shield and a tinned copper braided shield. Epec supports shielded cable assemblies ranging from low-voltage USB cables to Mil-STD-designed and certified cable systems.

Selecting the appropriate shielding solution requires consideration of:

• Signal type
• Program testing requirements
• Mechanical design constraints
• Flexibility and minimum bend radius

Because shielding can impact flexibility and increase both weight and cost, it is typically implemented when system requirements justify its use.

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Power Cable Manufacturing

General-purpose power cables commonly operate at less than 30 VDC or less than 120 VAC and can be manufactured using a variety of standard cable technologies.

Typical construction materials include:

• PVC jackets
• Tinned copper conductors
• Thermoplastic overmolds
• Pin and housing style connectors

Additional connector options include DC barrel power plugs and AC power plugs such as NEMA 5-15 and 1-15 styles. Epec also supports outdoor-rated power cable requirements using service cords such as SOW, SOOW, SJOOW, and SJT wire constructions.

Power Cable Specifications

Parameter	Value	Units
Typical DC operating voltage	Less than 30	VDC
Typical AC operating voltage	Less than 120	VAC
Common wire size	28	AWG

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Coaxial Cable Assemblies

Coaxial cable assemblies use a center conductor surrounded by dielectric insulation and enclosed within an outer shielded jacket. The center conductor and shield function as separate electrical circuits, creating a two-conductor design within a single cable structure.

Coaxial cable is commonly used for RF transmission and high-speed data applications. Frequencies above approximately 1–2 GHz generally require higher-performance materials and processing methods.

For lower-frequency applications, industry-standard cross sections such as RG316 coaxial cable can provide a cost-effective solution when paired with connector systems such as BNC or SMA male/female connectors.

Coaxial Cable Specifications

Parameter	Value	Units
High-speed performance threshold	1–2	GHz

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Industry-Specific Cable Assembly Solutions

Automotive Wire Harnesses

Automotive cable assemblies often require automotive-grade wire, extensive development programs, and PPAP submission support.

Common automotive requirements include:

• Waterproof connectors
• Dust-resistant connectors and caps
• SAE approval specifications
• Durable cable jackets such as XLPE
• Compression-molded silicone gaskets and seals
• Custom overmolds
• Cable grommets

Supported wire and material options include SAE J-1128, TXL, and GXL-rated wire constructions, along with overmold materials such as Santoprene.

Medical Device Cable Assemblies

Medical devices frequently require cable systems capable of carrying power, data, and high-resolution video while meeting specialized performance requirements.

Epec supports cable assemblies compatible with:

• Biocompatibility requirements
• Ethylene oxide sterilization
• Autoclave sterilization
• Exposure to isopropyl alcohol

The company also supports ISO 13485 accreditation requirements and maintains tooling for commonly used medical imaging connectors, including circular or high-resolution video connector configurations.

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Vertically Integrated Wire Harness Manufacturing

The cable assembly manufacturing process begins with the extrusion of a single conductor jacketed wire. Individual wires are then bundled to form multiconductor cable constructions before moving into assembly operations.

Cable materials can remain on spools until the remaining components of the assembly are ready for kitting and production, supporting a controlled manufacturing workflow from wire processing through final assembly.

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Frequently Asked Questions

Quick Links

• When would I use an overmold?
• When would I use strain relief?
• What should I know about coaxial cable?
• What should I know about connectors?
• How does ISO apply to medical cable assemblies?
• What are considerations for PVC?

When would I use an overmold?

Overmolding is used when additional protection is needed for electrical connections and internal cable components. It can also provide strain relief, waterproofing, ruggedization, and allow for custom mechanical features.

When would I use strain relief?

Strain relief is commonly added to connector terminations to improve durability and reduce stress on electrical connections. Epec incorporates strain relief through overmolded cable designs.

What should I know about coaxial cable?

Coaxial cable uses a center conductor, dielectric insulation, and an outer shielded jacket. It is commonly used for RF signals and high-speed data transmission.

What should I know about connectors?

Epec supports a wide variety of connector families, including D-Sub, USB, HDMI, DisplayPort, RCA, RJ45, RJ11, BNC, SMA, AC power connectors, and DC barrel connectors. Epec has existing crimp and assembly tooling for most connector manufacturers. Both standard and specialized connector configurations are supported.

How does ISO apply to medical cable assemblies?

Medical cable assemblies may require compliance with ISO 13485 accreditation requirements. Epec supports medical device cable projects that incorporate these requirements.

What are considerations for PVC?

PVC is one of the standard jacket materials used in power cable construction. It is commonly paired with tinned copper conductors, thermoplastic overmolds, and standard connector systems. PVC is a cost-effective and common material used for wire jackets.

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Vertically Integrated Wire Harness Manufacturing

Watch our cable assembly video as we review the steps in building a custom cable harness. The first step is to extrude a single conductor jacketed wire and then bundle it with other wires to form a multiconductor cable. Spooled wire can be stored until the rest of the assembly is ready to kit.

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Cost-Effective Cable Assembly Solutions

Managing performance requirements, manufacturability, and program costs requires careful evaluation at every stage of cable development. By supporting design, prototyping, production, testing considerations, and inventory management within a single program, Epec helps customers develop cable assemblies aligned with both technical and programmatic objectives.

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