What Information Is Needed for Custom Cable Assembly Design? A Guide to Drawings, Samples, and Testing Requirements

NEWS

26

2025

1. 📐 Engineering Drawings (or at Least a Sketch)

A technical drawing is the foundation of your cable design. Even a rough sketch is better than verbal instructions. It should include:

Overall cable length
Connector types and orientation
Wire gauge and number of conductors
Pin-to-pin configuration or wiring map
Breakouts, shielding, and strain relief design

Tip: If you don’t have a formal drawing, your EMS provider may help you create one—especially if you share reference photos or CAD files.

2. 🧪 Expected Performance & Testing Requirements

Define what “success” looks like for your cable. Your EMS partner needs to know how the assembly will be tested, and what performance standards it must meet. Common criteria include:

Continuity or insulation resistance test
Hi-pot (high potential) test for high-voltage cables
Pull or torque testing
Signal integrity (for data cables)
EMI shielding effectiveness

Be clear about pass/fail thresholds and if testing needs to be done on 100% of units or just a sample.

3. 🔁 Samples, Prototypes, or Similar References

If you’ve previously used a similar cable, providing a physical sample or photo will greatly speed up design alignment. Your EMS supplier can reverse-engineer or validate specs based on the sample, helping:

Reduce ambiguity
Confirm material compatibility
Ensure pinout and connector selection match

4. ��️ Environmental and Application Conditions

The end-use environment heavily influences cable selection—especially insulation and jacketing materials. Be prepared to share:

Operating temperature range
Waterproofing or moisture exposure (IP rating requirements)
Oil, solvent, or chemical exposure
Outdoor vs indoor usage
UV or flame resistance needs

The more your supplier knows, the better they can recommend suitable materials that balance performance and cost.

5. 📦 Delivery, Packaging, and Labeling Requirements

Even after the cables are assembled, logistics matter. You should also communicate:

Quantity per lot or reel
Special labeling or barcoding needs
Custom packaging (e.g., anti-static bags, coiled lengths, heat-sealed pouches)
Required certifications (RoHS, UL, ISO, etc.)

Final Thoughts

A successful cable assembly project doesn’t start on the production line—it starts with clear, complete communication.

By providing your EMS partner with the right drawings, test expectations, and application details upfront, you save time, reduce risk, and ensure the final product works exactly as expected.

If you're not sure where to begin, start with a sample or sketch—an experienced EMS team can guide you through the rest.

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