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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.

At a Glance: Cable Processing Capabilities

Comprehensive cable assembly processing capabilities spanning wire preparation, automation, shielding, ruggedization, testing, connector integration, and custom overmolded designs.
IPC/WHMA-A-620 compliant manufacturing supported by ISO-approved processes, design for manufacturability reviews, and cross-functional product teams focused on quality, reliability, and supply chain optimization.
Extensive material, conductor, connector, and testing options that enable fully customized cable assemblies for demanding commercial, industrial, medical, aerospace, and defense applications.

Our Cable Assembly Processing Capabilities Include:

Connector, Terminals, and Crimp Options

Wire to wire connectors
Wire to board connectors
Single and multi-row connectors
Spade terminals
Fork terminals
Ring terminals
Ferrules
Splicing and butt connections
Insulated/partially insulated terminals
Standard and gold plating options
IPC-620 compliant crimping connections
Automated and manual crimp stations available

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.

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.

Frequently Asked Questions

Quick Links

What types of cable assemblies can Epec manufacture?
How does Epec ensure quality and manufacturability throughout a project?
What customization and ruggedization options are available?
What conductor, insulation, and connector options are available?
What testing capabilities are available for cable assemblies?

What types of cable assemblies can Epec manufacture?

Epec supports a broad range of cable assembly technologies, from simple low-voltage hookup wires to highly engineered overmolded breakout assemblies and coaxial cable assemblies. Designs can be based on existing industry standards such as USB or developed as entirely custom solutions. This flexibility allows Epec to support applications across virtually every market sector while tailoring the design to specific electrical, mechanical, and environmental requirements.

How does Epec ensure quality and manufacturability throughout a project?

Every new cable assembly design undergoes a design for manufacturability review to identify opportunities for cost reduction, reliability improvements, and supply chain risk mitigation. Once a program moves into production, an integrated product team consisting of customer service, manufacturing, engineering, logistics, and quality personnel works together to verify that all specifications and objectives are met. Manufacturing is performed using ISO-approved processes, and all applicable cable assembly, testing, and inspection practices comply with IPC/WHMA-A-620 requirements.

What customization and ruggedization options are available?

Epec offers numerous customization features including overmolded strain reliefs, molded components, potting, epoxy encapsulation, custom housings, braiding, shielding, labels, circuit identification, and custom wraps. Additional options such as conductive overbraids, environmental sealing, and specialized material additives can further enhance durability. These capabilities help cable assemblies withstand demanding conditions such as vibration, moisture, abrasion, chemicals, and other environmental challenges.

What conductor, insulation, and connector options are available?

A wide variety of conductor materials, plating options, and insulation systems are supported. Conductor selections range from standard tinned copper to silver-plated and nickel-plated copper, while jacket materials include PVC, XLPE, silicone, polyurethane, PTFE, FEP, ETFE, and many other specialized compounds. Epec also supports connectors from leading manufacturers including Molex, Amphenol, Glenair, TE Connectivity, JST, Hirose, Samtec, Nicomatic, Canon, and Souriau, as well as compatible replacement components.

What testing capabilities are available for cable assemblies?

Testing services cover electrical, mechanical, environmental, and compliance requirements. Available testing includes continuity and resistance verification, HIPOT and dielectric testing, insertion loss and VSWR measurements, EMI/EMC testing, ESD testing, waterproof and pressure testing, leak detection, and custom fixture-based validation. Epec also utilizes environmental testing chambers capable of operational testing from -50°C to +80°C, helping ensure assemblies perform reliably under real-world operating conditions.

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.

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