Custom Wire Harness & Cable Assembly Manufacturer
Engineered for Medical, Industrial, and Automotive Applications | Prototype to High-Volume Production
Comprehensive Cable Assembly Solutions for Modern Industry
Our manufacturing footprint covers five core product families, each supported by dedicated process engineers and application-specific tooling. Need to optimize your current BOM? (Request DFM Review)
🔌 01 — Magnetic Pogo Pin Cable Assemblies
We engineered our magnetic pogo cables for medical wearables requiring tool-free, self-aligning connections. By integrating NdFeB magnets with our custom pogo pins, we eliminate mechanical fatigue and maintain < 30mΩ contact resistance under continuous vibration.
| Specification | Hard Data |
|---|---|
| Contact Resistance | ≤ 30 mΩ (per pin, tested at rated current) |
| Current Rating | Up to 5A per pin (Data pins: 1A max) |
| Mating Cycles | 10,000+ (IEC 60512 compliant) |
| IP Rating | IP67 waterproof certified (with integrated housing seal) |
| Custom Pitch | 1.0mm / 1.5mm / 2.0mm / 2.54mm |
ðŸ›¡ï¸ 02 — Overmolded Cable Assemblies
For industrial environments where cables face constant mechanical stress, our low-pressure overmolding (LPM) transforms a standard cable into a ruggedized component rated for up to 10 million flex cycles. It seals the connector-to-cable interface against moisture without damaging internal solder joints.
| Overmold Material | Shore Hardness | Temperature Range | Best For |
|---|---|---|---|
| TPU (Thermoplastic Polyurethane) | 70A – 95A | -40°C to +100°C | High-flex, abrasion-resistant robotic arms |
| PVC (Polyvinyl Chloride) | 60A – 90A | -20°C to +80°C | Cost-effective standard consumer goods |
| Nylon PA66 (Glass-filled) | Rigid | -40°C to +130°C | Structural strain relief, automotive connectors |
🚗 03 — Industrial & Automotive Wire Harnesses
Jiatel operates dedicated automotive-grade routing processes strictly compliant with IPC-A-620 Class 2 and Class 3. We monitor every single crimp with Crimp Force Monitoring (CFM).
- Wire Specs: GXL / TXL / SXL Automotive Grade.
- Connector Standards: SAE J1962 (OBD-II), Deutsch DT/DTP, AMP Superseal.
- Testing: 100% Continuity + Hi-Pot testing up to 3kV.
📱 04 — Precision FPC/FFC Connectivity
Our FPC (Flexible Printed Circuit) and FFC (Flexible Flat Cable) solutions maintain precise impedance control for high-speed data transmission in ultra-low-profile spaces.
- Pitch Options: 0.5mm / 0.8mm / 1.0mm / 1.25mm / 2.54mm.
- Assembly Capabilities: ACF bonding, Hot-bar soldering to PCB pads, Stiffener lamination (FR4, PI, Steel).
🔗 05 — IDC Flat Cable Assemblies
We deploy mass-termination IDC processes for high-density board-to-board interconnects, ensuring zero insulation damage and exact pitch alignment for server backplanes.
Technical Specifications & Manufacturing Capabilities
| Wire Gauge Range | 10 AWG to 32 AWG (Standard & High-Flex variants) |
| Connector Brands | JST, Molex, TE Connectivity, Hirose, Amphenol (Direct equivalents available for BOM cost reduction) |
| Termination Methods | Automatic Crimping (CFM monitored), Ultrasonic Welding, IDC, Solder-cup |
| Lead Time | Prototypes: 3-7 days. Production: 15-25 days. |
Expert DFM Support & The Jiatel Manufacturing Process
& BOM Check
(3–5 days)
(IPC-A-620)
(100% E-test)
Lifecycle Support
We do not perform sampling-based electrical testing on standard orders—every unit is tested, every time. Our automated test fixtures verify circuit continuity, shorts, and wiring sequence. High-voltage (Hi-Pot) testing and insulation resistance (>100 MΩ @ 500VDC) are conducted per your specifications.
Industries We Serve
| Industry | Typical Application | Jiatel Capability |
|---|---|---|
| Medical Devices | Patient monitoring, diagnostic imaging | Biocompatible Silicone/PTFE, UL 94V-0 compliant materials |
| EV & Automotive | OBD diagnostics, BMS wiring | GXL/TXL wire, SAE J1962, Hi-Pot to 1500V |
| Industrial Automation | Servo motor cables, PLC I/O harnesses | PUR jacketed high-flex cable, EMI shielding |
| Consumer IoT | Wearables, smart home devices | Sub-1mm pitch FPC, magnetic pogo pins |
FAQ
Q1: What is the minimum order quantity (MOQ) for custom wire harnesses?
For prototype and sample validation we accept trial quantities. Standard production orders start at 5,000 pcs, with trial quantities negotiable. Tooling starts from USD 600.
Q2: How long does it take to produce a prototype cable assembly?
DFM review is returned within 24 hours, and quotation with 2D footprint specs within 12 hours. Prototype samples take about 4 weeks. Mass production in 4–6 weeks applies to new-tooling projects; for an existing part the lead time is quoted per part.
Q3: Can Jiatel help if I only have a concept and no finished drawing?
Yes. Our engineering team can develop a manufacturable design from a block diagram, reference sample, or written specification. We generate 2D drawings for your approval before building any samples.
Q4: What drawing and schematic file formats do you accept?
We process .PDF, .DWG, .DXF, .STEP, .IGES, and SolidWorks (.SLDPRT/.SLDASM), as well as schematic files from Altium, KiCad, Eagle, and OrCAD.
Q5: Do you provide RoHS compliance documentation?
All assemblies use RoHS 3 (EU 2015/863) compliant materials. Full material disclosure (FMD) reports are available on request.
Q6: Can you replicate an existing assembly or provide cross-match / equivalent parts for a sample?
Yes. Provide a physical sample or detailed photographs, and our engineers will analyze the specifications, create engineering drawings, and produce equivalent matching samples for legacy equipment maintenance and replacement.
Q7: What quality standards do your wire harnesses conform to?
Our production strictly conforms to IPC-A-620 Revision E. Customers can specify Class 2 (general electronics) or Class 3 (high reliability/continuous service) requirements.
Q8: How do I get a quote?
Upload your drawing or BOM using the form below. Our engineering team will review your data and respond with a detailed quote and Free DFM feedback within 24 business hours.
Start Your Custom Cable Project
- ✅ Free DFM Review — returned within 24 business hours
- ✅ No MOQ for samples — NRE-free prototyping for qualified projects
