Frequently Asked Questions

All cable assemblies and wire harnesses are custom-built to OEM specifications. We do not offer standard or off-the-shelf products. Every design is built to match your drawings, BOMs, and quality requirements.

Our process includes:

• Wire cutting, stripping, and crimping with high-speed automated and semi-automated equipment
• Connector and terminal application using calibrated presses
• Ultrasonic welding or soldering where required
• Overbraiding, sleeving, and shielding for EMI protection
• Labeling and serialization based on customer instructions
• Routing into custom harness boards for complex builds
• Each step is documented and controlled according to IPC/WHMA-A-620 standards.
• Electrical testing and QA inspections

We provide:

• 100% continuity and Hipot testing
• Pull-force testing to ensure crimp integrity
• Visual inspections at multiple production stages
• Functional testing based on customer needs
• Detailed inspection and test records are provided with each shipment when requested.

Our cable and harness assembly lines operate under certified ISO 9001, ISO 14001, IATF 16949, AS9100D, and ISO 13485 quality systems, as well as certifications from UL, CSA, US FDA, CE marking, China NMPA, and Singapore HSA.

We build to customer designs across multiple sectors, including:

• Aerospace
• Agricultural and heavy equipment
• Automotive & Electric Vehicles
• Communication, Telecom, Networking
• Consumer and Commercial Electronics
• Industrial Automation & Controls
• Medical Devices & Equipment
• Robotics & Warehouse Systems

Yes. We offer flexible production support:

• Prototypes and first articles for design validation
• Low-volume pre-production for pilot runs
• High-volume production in Southeast Asia for cost efficiency

Yes, unless otherwise specified by the customer. We ensure full compliance with environmental directives.

We support:

• AWG 2–38, stranded or solid
• Special insulation types such as Teflon (PTFE), XLPE, PVC, and Silicone
• Custom cable for multi-conductor cables, shielded cables, twisted pair, and coaxial assemblies
• Jacketed cables (for data, signal, or power)

We build each harness on custom layout boards (jigs) using:

• Pin-to-pin diagrams
• Wire maps
• Labeling and color coding
• Wire and branch bundling with specific breakouts, taping patterns, and routing paths

This ensures repeatability, accuracy, and reduces human error on large builds.

Yes. We support:

• 360° EMI terminations using solder sleeves or clamps
• Drain wire connection to ground or specific pins
• Overbraid shielding and conductive wraps

Yes. We offer:

• Inkjet or laser wire marking
• Heat-shrink or wraparound labels
• QR or barcode serialization
• Custom BOM-driven labeling instructions

Yes. Capabilities include:

• Overmolding with PVC/TPU/TPE
• Heat-shrink strain reliefs
• Custom boots and backshells
• Potting for vibration and fluid protection

All crimp terminations are done according to IPC/WHMA-A-620 guidelines and validated using:

• Pull force testing (MIL-STD-202 Method 211)
• Crimp height and width measurements
• Cross-sectional analysis for high-reliability applications

Yes. We have long-standing sourcing relationships across Asia and globally. If a part is obsolete or constrained, we can help with equivalent substitutions, cost-down alternatives, or customer-approved second sources.

• Source global or local equivalents
• Identify cost-effective alternatives
• Suggest form-fit-function substitutes for obsolete parts

We use:

• Revision-controlled document systems
• ECO review workflows
• Archived versions of BOMs and drawings
• Traveler sheets and work instructions updated per the latest revision

On request, we include:

• First Article Inspection (FAI)
• PPAP (Level 3) documentation
• Test reports and certificates of compliance
• Serialized lot and build records
• Inspection checklists
• Final QA sign-off records

We provide:

• Lot-level and serial-level traceability for wire, terminals, and connectors
• Full traceability per harness ID, date code, and operator
• Scan-and-store systems for quality assurance and recall traceability

We offer:

• SMT (including 01005 packages)
• Through-hole (wave, selective, hand)
• Mixed-technology builds
• BGA, QFN, LGA with X-ray inspection
• Double-sided reflow, selective soldering, wave soldering
• Conformal coating, potting, and encapsulation (as needed)
• All assemblies are built to IPC-A-610 standards, Class II or III depending on the application.

Yes. We perform:

• AOI (Automated Optical Inspection)
• X-ray inspection for BGA and voids
• In-Circuit Testing (ICT)
• Functional Testing (FCT)
• Boundary scan and custom firmware loading if needed

• Leaded and lead-free reflow ovens (RoHS-compliant)
• Wave soldering (for THT)
• Selective soldering (for dense boards)
• Hand soldering for odd-forms or mods

• Component size: 01005 packages (0.4mm x 0.2mm) and up
• Minimum pitch: 0.3mm
• Placement accuracy: ±25µm @ 3
• High-precision placement is validated by SPI (Solder Paste Inspection) and AOI systems.

We require:

• Gerber files or ODB++
• BOM with MPNs and descriptions
• XY centroid file
• Assembly drawing and notes
• Optional: test files, firmware instructions

Yes. Our engineering team provides:

• Design for Manufacturability (DFM)
• Design for Testability (DFT)
• Solder joint and thermal analysis
• Test point and programming access optimization

Yes. We can program:

• Microcontrollers (via JTAG, ISP, SWD)
• Firmware loading for MCUs, EEPROMs, CPLDs, and FPGAs
• Testing with customer-supplied golden units

Yes. We are capable of building toIPC-A-610 Class III and provide inspection reports, FAI, and QA sign-off documentation.

Yes. We support:

• Acrylic, silicone, urethane coatings
• UV-traceable inspection
• Custom masking and curing
• Encapsulation for mission-critical or ruggedized products

Yes. Our box-build integration includes:

• Electromechanical and mechanical assembly (enclosures, hardware, displays, pump, motor, etc.)
• PCBAs into metal/plastic enclosures
• Cable harness and connector installation
• Final testing and functional verification
• Perform final test, labeling, and packaging per customer instructions

We support:

• Prototypes and first articles for design validation
• Low-volume pre-production for pilot runs
• High-volume production

We support high-mix, low-volume builds. We can build in Southeast Asia for cost savings or final assembly in the U.S. as needed.

Our PCB assemblies and box-build integration operate under certified ISO 9001, ISO 14001, IATF 16949, AS9100D, and ISO 13485 quality systems, as well as certifications from UL, CSA, US FDA, CE marking, China NMPA, and Singapore HSA.

Yes. We have dedicated RoHS (lead-free) and leaded soldering lines, separated by process and tooling to maintain compliance and cleanliness.

Our entire PCBA operation follows strict ESD-safe protocols:

• Test by Wrist Strap/Footwear Tester
• ESD Workbench
• Ionized air blowers, ESD mats, grounded wrist straps
• ESD-safe bags and packaging materials
• Routine calibration of ESD tools
• Compliance with ANSI/ESD S20.20