Custom Cable Assembly & Turnkey EMS Manufacturing Solutions
CONSONS provides cable assembly services covering crimping, soldering, connector termination, overmolding, electrical testing, and final inspection. As an EMS provider, we integrate cable assembly with advanced PCB manufacturing, FPC production, and injection molding in one manufacturing process, connecting internal circuits with external interfaces. Our one-stop solution supports wire gauges from AWG 4 to AWG 32 and is suitable for complete Box-Build assembly in medical, automotive, and industrial equipment.
We use advanced wire-cutting and crimping machines to achieve micron-level terminal alignment. We support original connectors and certified equivalents. Our capabilities include multi-branch heavy-duty shielded cables, IP67 waterproof overmolding, and customized strain-relief designs for harsh operating environments. We verify connection reliability through digital continuity testing to IPC-A-620 Class 3, 1500V Hi-Pot testing, and quantitative terminal pull-force testing up to 100 kg.
Submit your cable drawing, BOM, or sample to get a custom Cable Assembly solution.
Cable Assembly Types
We use automated wire stripping and precision terminal crimping to provide mechanically stable, solderless electrical contact for high-vibration application environments like automotive or industrial.
The secure electrical joints are created with hand soldering techniques, which deliver high shielding and support high frequency signals and aerospace applications.
Instead of individual wire stripping, the insulation displacement technology provides mass line connections, offering efficient cable routing for dense internal electronics and data telecommunications.
The injection molding technology is integrated to seal cable and connector interfaces with protective material, offering protection against demanding operating conditions, like strain relief or waterproofing.
The highly customizable lead configurations with ring, spade, or quick-disconnect terminals seamlessly combine power and ground wire termination across electrical panels and support straightforward installation.
High-Speed Cable Assembly for Demanding Data Transmission
By optimizing conductor selection, cable geometry, connector matching, and termination, we can achieve high data integrity. The precision impedance matching, suitable materials, and high-bandwidth protocols prevent packet loss. As a turnkey EMS provider, we integrate advanced copper and fiber solutions with optimized PCBA design, which ensures end-to-end signal routing under high-throughput conditions. From prototypes to high-volume manufacturing, our high-speed line reduces bit-error rates, helping your high-frequency network and server infrastructure operate at peak performance.
Advanced Shielding for Cleaner Signal Performance
CONSONS uses multi-layered shielding architectures and specialized drain wires to protect sensitive signals from EMI/RFI and unwanted coupling. According to your requirements, we can cover the conductors with foil, braid, or combined configurations. We coordinate shielding coverage, grounding paths, connector termination, and cable construction to maintain effective signal protection. For communication, measurement, control, and other electronics where electromagnetic noise can affect signal stability, our advanced shielding technology protects your critical analog and digital data lines from disruptive crosstalk.
Stronger Terminations for Demanding Industrial Applications
With automated precision crimping and high-reliability soldering, we create vibration-resistant, pull-tested connections. We can customize overmolding and ruggedized strain relief to help these rugged terminations further resist thermal cycling, moisture, and chemical exposure in the harsh factory environments. The termination dimensions, conductor positioning, and assembly consistency are also strictly controlled to reduce loose contacts or connection failure risks. Our solutions ensure continuous power and ground termination and support operation in industrial automation, robotics, and control equipment, reducing your equipment downtime.
Specification
| Cable Assembly Type | Crimp, Solder, IDC, Overmolded, Terminal |
| Cable Structure | Single-Conductor, Multi-Conductor, Flat, Ribbon, Twisted Pair, Shielded, Coaxial |
| Connection Configuration | Wire-to-Wire, Wire-to-Board, Board-to-Board, Board-to-Wire, Connector-to-Connector |
| Termination Methods | Crimping, Soldering, IDC, Terminal Termination |
| Connector Types | JST, Molex, TE Connectivity, USB, D-Sub, Circular, and Customized Connectors (Compatible With Customer-Specified Connector Brands And Models) |
| Conductor Material | Copper, Tinned Copper |
| Wire Gauge | Customized according to project requirements |
| Cable Length | Customized |
| Shielding | Foil, Braid, Combined Shielding |
| Jacket Materials | PVC, PUR, TPE, and other specified materials |
| Minimum Conductor Spacing | Down to 0.10 mm where applicable |
| Testing | Continuity, Insulation Resistance, Hi-Pot, Pinout Verification |
| Overmolding | Available |
| Labeling | Customized |
| Packaging | Standard or customized packaging |
| Manufacturing Support | OEM, ODM, EMS, DFM Support |
| Related Manufacturing | PCB, PCBA, FPC, Injection Molding, Automated Assembly, Final Assembly |
Applications of Cable Assembly Services
We simplify wiring and improve connection stability in harsh production environments. Our rugged industrial cable assemblies with high vibration terminations, heavy shielding, and customized overmolding keep PLCs, sensors, servo systems, and control equipment connected dependably.
For non-stop robotic motion, we provide dynamic torsional-resistant cable assemblies that withstand millions of flex cycles without signal loss. The cable lengths, connectors, routing structures, and strain relief are customized to withstand repeated movement and reduce connection-related downtime.
Telecom infrastructures have strict signal requirements. We combine advanced FPC manufacturing, precision soldering, and multi-layer EMI shielding to guarantee a clear signal for communication equipment. From signal interconnections to power connections, we ensure consistent assembly quality.
We can customize data center cable assemblies with matched impedance and high speed for high-bandwidth servers and networking hardware to support high-bandwidth data transmission. Our complete PCBA and turnkey cable routing help minimize bit-error rates under high-speed transmission conditions, securing your tech infrastructure.
Healthcare applications are sensitive and have demanding requirements. Our medical electronic cable assembly service is supported by an ISO 13485-certified quality management system, helping you meet the quality and traceability requirements of medical device manufacturing. We offer biocompatible, overmolded cable assemblies.
The wire harnesses we use for automotive applications are certified to IATF 16949 standards. For complex vehicle wiring that connects sensors, ECUs, lighting systems, and electronic modules, our solutions help you improve connection consistency and support reliable assembly throughout vehicle systems.
Yes. For complex equipment layouts requiring multiple power, signal, or control connections from a common cable structure, we specialize in customizing complex multi-branch wire harness designs. We use 3D CAD tools plus formboard software to map complex break-out configurations, routing angles, and branch lengths.
During manufacturing, our multi-branch harnesses have clear wire markings printed with a laser, reducing assembly errors. At branch transitions, we use heat-shrink tubing, braided sleeving, or custom overmolding to secure, ensuring robust strain relief.
The flexibility of multi-branch branching supports consolidating multiple connections into one organized harness assembly with reliable electrical continuity and mechanical stability.
We choose material and pitch configurations according to different electrical, mechanical, and space requirements. Whether you need secure connector mating or enhanced conductivity, we can meet your requirements.
Our versatile FFC and FPC assemblies are manufactured with premium PI and PET, tailored for tight, dynamic environments. Our substrate options feature varying copper foil thicknesses from 0.5oz to 2oz.
Shielding additives such as aluminum foil, conductive tape, or silver ink help resist EMI. For design flexibility, besides standard 1.25mm or 2.54mm options, we also support micro-pitches down to 0.3mm, 0.5mm, and 1.0mm.
For cable stripping and cutting, we use precision automatic wire cutting and stripping machines for precise strip lengths without damaging copper strands. For high-precision terminal crimping, we deploy fully automatic crimping machines featuring integrated crimp force monitors, which analyze every crimp in real time, rejecting any deviations in terminal height or wire placement.
Our crimping dies have micron-level cavity tolerances, ensuring gas-tight compression without wire gaps or strand damage. The terminal applicators use precise dynamic feeding to align terminals exactly on the center line so we can make rapid changeovers. Our advanced setup guarantees that every single termination meets specified requirements.
First, we check the assembly visually to preliminarily verify connector orientation, terminal positioning, cable length, labeling, and workmanship. We check continuity and detect opens or shorts with automated electrical testing on cable analyzers.
We run high-voltage insulation and Hi-Pot tests to prevent dielectric breakdown. Mechanically, we perform standardized pull-force tests to confirm terminal crimp integrity and flex testing for dynamic lines.
For specialized high-speed assemblies, time-domain reflectometry and network analyzers verify impedance and signal attenuation, so that the customized products we provide are fully operational and flawless. The specific tests are established according to your drawings or approved samples.
First, we set the required IP rating according to the intended installation environment and specification. Verification can then follow the applicable IP testing requirements. During DFM and injection molding, we check material bonding between cable jackets and overmold resins. After production, we perform vacuum and differential air-leak testing with customized test fixtures to detect microscopic seal failures without damaging products.
For destructive or environmental batch validation, we conduct continuous water submersion testing and high-pressure hot-water jet testing with specialized chambers. Our multi-stage checks confirm the finished products we offer for use in extreme weather and marine environments with heavy washdown sanitation protocols.
As a one-stop EMS provider, we solve EMI problems across both cables and PCBA sub-assemblies. During the design, we route high-speed or noise-sensitive cables away from high-current or high-noise sources where practical.
For the PCBA, we optimize layer stack-ups, ground planes, and component placement to restrict crosstalk. For custom cables, we design robust, multi-layered shielding architectures utilizing braided copper, aluminum foil, and specialized drain wires.
We ensure shielding termination at the connector interface with conductive overmolding or metal backshells. Combined with ferrites and filtered connectors where required, our measures help control EMI and support compliance with applicable EMC requirements.