What is the difference between a cable assembly and a wire harness?

A cable assembly is one cable — single-core, multicore, coaxial or ribbon — cut to length with a connector or terminal at each end. A wire harness is a loom: many wires bundled, branched and broken out to several connectors, routed to a drawing’s geometry. Most equipment uses both. We build both, and the same people quote them.

Can you build from a sample instead of a drawing?

Yes. We document the sample as a drawing first and ask you to approve that, so the part is reproducible and the second batch matches the first. Building straight from a sample is how a tolerance gets lost.

What length tolerance do you work to?

The one on your drawing. Where a drawing does not state it, we propose a tolerance on the quotation and build to that — a length without a tolerance is not a specification.

Do you make RF and coaxial assemblies?

Yes — 50 Ω and 75 Ω coaxial with SMA, SMB, MCX, MMCX, BNC, FAKRA and U.FL terminations, in PVC, LSZH or PTFE-dielectric constructions. Assemblies are swept for insertion loss before dispatch, not only checked for continuity.

Do you supply outside India?

Yes. We quote in INR, EUR or USD, ship under EXW, FCA, FOB, CIF or DAP (Incoterms® 2020), and provide the RoHS and REACH declarations an EU or UK importer needs. The Incoterm for an order is fixed on the quotation.

Is there a minimum order quantity?

No. Prototypes and small batches are quoted like any other job. The quotation is broken out by material and labour, so you can see what changes when the volume does.

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Capability

Cable assembly manufacturer in India

A cable assembly is a finished part: cable cut to length, a connector on each end, the screen terminated properly, every circuit tested, the part labelled. That is what we ship — in single-core, multicore, twisted-pair, coaxial and ribbon construction, from prototype quantities up.

Send a drawing +91 95616 19702

Manufactured in: India, supplied internationally
Quoted in: INR, EUR or USD
Workmanship: IPC/WHMA-A-620
Tested: 100% continuity before dispatch

Assembly types

Point-to-point and multi-drop assemblies in single, multicore, screened or twisted-pair construction
Screened multicore for PLC, drive and encoder interconnect, with the screen terminated 360° at the backshell rather than pigtailed onto a pin
Twisted-pair drops for RS-485, CAN, LIN and fieldbus, with the twist held right up to the contact so the pair stays balanced
Coaxial and RF assemblies with SMA, SMB, MCX, MMCX, BNC, FAKRA and U.FL terminations, swept for loss before dispatch
Flat ribbon with IDC terminations — daisy-chained, keyed and polarised, in the pitch your board is laid out for
Power and battery leads with ring, fork, bullet and blade terminals, insulated or heat-shrunk
M12 and circular sensor leads, coded and sealed, for machines and outdoor equipment
Overmoulded and sealed terminations for assemblies that move, flex or sit in wash-down

Cable constructions and jackets

The cable is specified against the duty, not the other way round. Six core architectures and five jacket materials cover most of what arrives, and the combinations we build are the ones on the cable builder on our main page — every lit path there is a construction we have made.

Core architectures: Single core, Multicore shielded, Twisted pair, Screened multipair, Coaxial / RF, Flat ribbon (FRC)
Jacket materials: High-flex silicone, PTFE / Teflon, PUR polyurethane, Halogen-free LSZH, Standard PVC
Screening: Overall foil, overall braid, foil and braid, and individually screened pairs — terminated to a backshell, a drain wire or a ferrule as the connector allows
Impedance: 50 Ω and 75 Ω coaxial; 100 Ω and 120 Ω twisted pair for Ethernet and fieldbus
Identification: Wire numbers and heat-shrink markers to your schedule, and your part number and revision on every assembly

Screen termination and signal integrity

Most of what separates a cable assembly that works from one that passes a buzz test happens at the ends. A screen pigtailed onto a pin is an antenna; terminated 360° at the backshell it is a screen. A twisted pair opened up for the last 40 mm before the contact is no longer a twisted pair at the frequency that matters.

So the screen is terminated to the backshell wherever the connector has one, and to a drain wire only where it does not. On vehicle runs the screen is grounded at one end only, to avoid a loop through the chassis; on drive cables it is bonded at both, to keep the inverter switching where it belongs. Twist is held to the contact. Coaxial assemblies are swept for insertion loss, not just checked for continuity.

If your drawing does not say how the screen should be terminated, we will ask, and propose the termination that suits the connector and the circuit — because the answer changes the part.

Testing

Every assembly is continuity-tested on every circuit, with short and mis-wire checks between adjacent pins. Crimp height is measured against the contact manufacturer’s range and pull force is sample-tested. Insulation resistance and hipot are applied where the assembly carries mains or works in a damp environment.

Crimp heightMeasured with a micrometer against the contact manufacturer's specified range — the single best indicator of a sound crimp.
Pull-force testDestructive sample testing to confirm the crimp meets the pull-out force the contact is rated for.
Continuity, 100%Every assembly, every circuit. Confirms the pin-out matches the drawing and there are no opens.
Short and mis-wireChecks adjacent circuits are isolated and no two pins are transposed — the failure that passes a simple buzz test.
Insulation resistanceApplied where the assembly carries mains or works in a damp environment.
Hipot / dielectricHigh-potential withstand testing on request for safety-critical and mains-connected assemblies.
Visual and dimensionalBranch lengths, breakout positions, label placement, sleeving coverage and housing seating checked against the drawing.
First articleA first-off sample submitted for your sign-off before the batch runs, with a dimensional and electrical report.
TraceabilityCable and contact lots recorded against the job, so a field question can be traced back to the material used.

From drawing to dispatch

The job runs through the same nine steps as a harness: drawing review and sourcing before a costed quotation; cut, terminate, verify the crimp and dress on the bench; electrical test, label and pack before it ships. Each step is recorded against the job, so a question three months later has an answer. The full sequence is set out on our main page under Process.

Standards we build to

IPC/WHMA-A-620Cable and wire harness assembliesThe harness industry’s workmanship standard: acceptance criteria for crimping, soldering, splicing, lacing, moulding and marking. Class is agreed per job — tell us which one your drawing calls for.
IPC J-STD-001Soldered electrical assembliesSolder joint requirements, applied where a drawing calls for soldered terminations rather than crimped contacts.
EN / IEC 60204-1Electrical equipment of machinesConductor colour coding, identification and protective bonding for looms going into machinery destined for the EU. Tell us your machine is built to it and we wire to its conventions rather than to general practice.
RoHSDirective 2011/65/EUHousings, contacts, cable and solder specified as RoHS compliant by default, with a written declaration for the parts actually used issued on request — which is what an EU importer needs for their technical file. Say so at enquiry if your application is exempt and needs otherwise.
REACHRegulation (EC) 1907/2006Substances of very high concern declared against the current ECHA candidate list, for the material actually used on your job. Article 33 information is provided on request at no charge.
UL 758 AWMAppliance wiring materialUL-recognised wire and cable specified where your end product is itself UL listed and the harness has to sit inside that listing.

Supplying from India to customers abroad

We quote in INR, EUR or USD and ship under EXW, FCA, FOB, CIF or DAP (Incoterms® 2020), with the rule for an order fixed on the quotation. RoHS and REACH declarations are issued for the parts actually used, which is what an EU importer needs for the technical file. Correspondence is in English.

What to send for a quote

For a cable assembly the essentials are the cable specification, the connector part numbers at each end, the length and its tolerance, and the quantity. Anything else on this list helps; nothing on it is required to start.

Drawing or sketchEven a hand sketch with lengths marked is enough to start
Wire list or scheduleFrom-to, circuit numbers, gauge and colour if you have it
Connector part numbersHousing and contact numbers, or a photo of the mating part
Cable specificationType, gauge, core count, screening, temperature rating
Lengths and toleranceOverall length, branch lengths, breakout positions
Quantity and schedulePrototype count, first batch and expected annual volume
EnvironmentTemperature, flexing, moisture, chemicals, vibration
Approvals requiredAny flammability, smoke or sector-specific requirement

Questions we are asked

What is the difference between a cable assembly and a wire harness?: A cable assembly is one cable — single-core, multicore, coaxial or ribbon — cut to length with a connector or terminal at each end. A wire harness is a loom: many wires bundled, branched and broken out to several connectors, routed to a drawing’s geometry. Most equipment uses both. We build both, and the same people quote them.
Can you build from a sample instead of a drawing?: Yes. We document the sample as a drawing first and ask you to approve that, so the part is reproducible and the second batch matches the first. Building straight from a sample is how a tolerance gets lost.
What length tolerance do you work to?: The one on your drawing. Where a drawing does not state it, we propose a tolerance on the quotation and build to that — a length without a tolerance is not a specification.
Do you make RF and coaxial assemblies?: Yes — 50 Ω and 75 Ω coaxial with SMA, SMB, MCX, MMCX, BNC, FAKRA and U.FL terminations, in PVC, LSZH or PTFE-dielectric constructions. Assemblies are swept for insertion loss before dispatch, not only checked for continuity.
Do you supply outside India?: Yes. We quote in INR, EUR or USD, ship under EXW, FCA, FOB, CIF or DAP (Incoterms® 2020), and provide the RoHS and REACH declarations an EU or UK importer needs. The Incoterm for an order is fixed on the quotation.
Is there a minimum order quantity?: No. Prototypes and small batches are quoted like any other job. The quotation is broken out by material and labour, so you can see what changes when the volume does.