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 |
🛡️ 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 Listed wire |
| 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, Jiatel has zero MOQ. You can order a single assembly. Production runs are typically 50-100 pieces, though we frequently support low-volume runs for medical and aerospace applications.
Q2: How long does it take to produce a prototype cable assembly?
Standard prototype lead time is 3-5 business days from receipt of an approved drawing and confirmed BOM. For urgent NPI projects, we offer an expedited 24-48 hour prototyping service.
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 and REACH compliance documentation?
Yes. All assemblies use RoHS 3 (EU 2015/863) compliant materials. REACH SVHC declarations and full material disclosure (FMD) reports are available upon request within 3-5 business days.
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
