Cable Assemblies

Cable assemblies serve as the nervous system for powered, smart devices and are very similar to wire harnesses. They consist of  larger/heavy gauge cables or multiple conductors (“wires”) protected inside one singular outer jacket with terminals at both ends. These termination points allow them to be connected to other electrical components within a larger system.

Cable Assemblies vs Wire Harnesses

The key differences are that cable assemblies consists of multiple conductors housed inside one singular jacket often they have a more ruggedized construction and utilize different assembly techniques because they are designed for specific environments which may have one or more special requirements regarding:

• environmental requirements such as heat or cold tolerance
  friction protection
• moisture resistance
• compression protection
• size or shape

When designing custom cables, the wires and conductors used in the assembly typically have a more heavy-duty cover/jacketing or use a larger gauge wire to protect the conductors and meet the needs of more demanding applications. 

Sheathing Materials for Cable Assemblies

Popular sheathing materials include:

• vinyl
• thermoplastic rubber
• shrink wrapped thermoplastic
• copper braid
• tinned braid
• foil

DECA’s Capabilities

DECA Manufacturing will produce the cable assemblies you need for just about any environment your parts must function in. Our production facility can:

• work with a variety of wire gauges, terminals, connectors, conductors and multi-conductors
• support a variety of cable types – coaxial, PTFE, stranded or solid
• support a range of wire gauge up to 1/0 to 28 AWG
• overmold in-house to enclose, protect, and finish cables with strain relief
• hand solder with precision to IPC/WHMA-A-620 standards

At DECA we offer

• high-speed automated cut/strip processing
• terminal press crimping with magnification
• crimp force monitoring.

We have a multitude of applicators and hand tools in our facility, and can do any hand assembly your project requires. We can obtain specialized connectors and military spec components required for specialized cable assemblies and handle specialized layouts. DECA has access to the materials, tools and expertise to build the customized cable assemblies your application requires.

Starting Your Project

To fabricate your wire harness we need the following information:

• prints, drawings or schematics
• bill of materials (BOM)
• approved vendor list (AVL)

Testing and quality control

All our products are 100% inspected and many are 100% tested leveraging Cirris brand test systems to make sure the products function to the required level.

Learn more about our commitment to quality.