Custom Cable Assembly

We can provide cables with flat ribbons, weatherproofing, and soldered terminations, among other features. We offer options of VGA and USB connector points. Other connectors can also be designed as per the requirement. These are used in assorted industries, including manufacturing, oil and gas, military, and aerospace. Applications can range from multi-termination to point-to-point assemblies.

Custom D-Sub Cable Assembly

Our custom D-Sub cable assemblies are designed to meet unique requirements related to computers and communications. The cables can be provided in a range of gauges, from 24 to 30 AWG. They are designed with standard connectors, flexible PVC jackets, and braided copper and aluminum insulation shielding. We provide them for applications such as adapter boards, camera linking, printing machines, etc.

Custom Ethernet Cable Assembly

Fluid and fast data transmission over a network is not possible without the right Ethernet cable assembly. At Carr Mfg., we provide custom Ethernet assemblies that can meet any network requirement. Our Ethernet cables are designed for large, high speed, and powerful networks. We offer Cat 5, 6, and RJ45 cable types. They can be used for military, video, voice, and data applications.

Custom LED Cable Assembly

Custom LED assemblies provide solutions for a myriad of thermal, electrical, and mechanical requirements. Carr Mfg.’s LED assemblies provide a range of consistent LED luminosity outputs. Custom hardware and connectors help complete interconnect needs. They can be used with indicator panels in aerospace and defense. They are suitable for automotive navigation systems and interior lighting. They are ideal for panels used in telecommunications.

Custom Medical Cable Assembly

Custom medical assemblies are known for their reliability, supporting equipment in emergency situations. Customers choose these products for their performance accuracy, and hygienic components and construction. These are designed to provide consistent signal integrity, while providing performance in many areas. These include pulse oximetry, patient monitoring, and temperature monitoring. Custom medical assemblies can be used in digital medical inspections, pad printing, and robotic loading, among others.


Custom Power Cable Assembly

As the name suggests, custom power cable assemblies can be used to support custom power supplies equipment. They can support different voltage levels, while working with DC power supplies. Custom power assemblies can be designed as crimp-and-poke, soldering, and high voltage. Generally, these assemblies consist of simple jumpers. We can also design custom power assembly options for bared terminations.

Custom Power Cord

At USCABLES, we have the capabilities to provide custom power cords in a variety of sizes, types, and styles. We can design cords with custom ends, such as female 3 prong, mate and lock, and strip and tin, among others. We can also meet your custom color, jacket, and insulation requirements. They are designed for specific applications, such as water repulsion, and impact and pressure resistance.

Custom Sensor Assembly

Custom sensor assemblies can be provided in options such as transmitters, RTDS, and thermocouples. Depending on the application requirements, we can provide custom thermowells, fittings, multi axis sensors, and connection heads. Other customized options include tip sensitive heads, flame and explosion proof, and sanitary sensors. Custom sensor assemblies can be installed in equipment and applications of industrial, medical, transportation, testing, and aerospace.

Custom Switch Assembly

Custom switch assemblies can be made either from scratch, or by modifying existing assembly designs. We can take a range of requirements, including high density, rocker switches, sealed, and toggle switches. We can provide custom switches for projects with mid to high volume projects. If required, FPC and membrane requirements can also be taken care of. Our custom switch assemblies can be installed with existing or newly designed systems.

Electro-Mechanical Assemblies

At USCABLES, we combine a staff of highly trained operators with the experience needed to successfully deliver even the most complex electro-mechanical assemblies.

USCABLES integrates surface mount technology PCBs and flex circuit assemblies, built on-site, into electro-mechanical assemblies for more than half of our customers.

For every project, our manufacturing engineers create detailed assembly drawings and process maps to document the production of electro-mechanical assemblies ranging from simple to complex. Common build-items include:

  • Box Builds
  • Enclosures
  • Chassis
  • LED Lights 
  • Medical Devices
  • Optical Assemblies
  • Power Panel Assemblies
  •  Harness Assembly

Wire Harness Assembly


Custom Wire Harnesses

We design and develop custom wire harnesses from UL approved wires and connectors of different types and sizes. The number of conductors, their terminal style and production quantity, are decided according to specific customers need. Cable harnesses for any requirement in computers, instruments, telecommunication products, and several other applications, can be precision handled by us. Complete solutions, ranging from innovative wire harness designs/patterns to turnkey assemblies, are offered to meet specific client requirements. Before delivery, these are 100% electrically tested to eliminate infiltration of defective pieces. Upon approval from the client, the required volume of wire harnesses is manufactured with high repeat-ability and detailed records are maintained for trace-ability. With a variety of pneumatic and electric terminating equipment from AMP, TRW, Berg, Molex, Midland Ross, plus Panduit, we easily adapt to large and prototype production quantities. Fully tested, our wire harnesses guarantee electrical and physical integrity.

Wire Harness Assembly

With several years of experience in component selection and manufacturing sequences, we can handle all type of wire harness jobs. Be it an assembly of few inches or a few yards, your wire harness assembly will be precisely assembled and 100 percent electrically tested, ensuring that it is ready for plug in.

We conform to a range of standards for electronic and electrical wiring products. Apart from testing outgoing wire harnesses, our quality control team members also perform inspections of all incoming sourced electrical components prior to assembly, to ensure quality. Visual and dimensional inspection is also performed along with intermediate assembly testing where applicable.

In addition, our design team works closely with our clients to review drawings, assist in the design phase, and point out any potential problems with the design prior to assembly. We also provide this service for cable assembly rework, on request.

Electrical Cables

Manufacturing custom electrical cables with in-house design, prototyping, and assembly services is our specialty. Our fabrication prototypes with appropriate connector orientation, proper length, and break out or bend locations, helps industrial OEMs eliminate budget as well as scheduling problems. An extensive stock of molds to facilitate custom cable manufacturing exempts our customers from spending additionally on tooling.

In the past, we have built lengthy control cables  to support bulk material conveyor systems. Light gauge telecom cables, heavy gauge cables for DC applications, power cord cables, wiring cables, and other types of UL approved electrical cables can also be custom manufactured by us. Cables can be multi-shielded, PVC insulated, as well as made to customer-specified thickness, diameter, weight, and current rating. In addition, they are 100% electrical tested with the help of continuity test equipment prior to delivery.

Flat ribbon cable assembly, computer printer/modem/USB cable assembly, power cord cable assembly, and production of light gauge assemblies for telecom applications are some of our specialty jobs. Value added operations, such as cable assembly rework, and a variety of other product adjustments to revise existing assemblies, also form a part of our services. 

Custom Molded Cable Assembly

We produce molded cable assemblies, using different types of connectors and electronic or computer interface cables, to match customer designs. Our in-house injection molding capabilities help us to over-mold assemblies from any plastic material. The injection-molding unit at our facility is dedicated for over molding electronic cable assemblies.

Our designers work closely with the client, review their drawings, and point out any potential problems before the commencement of cable assembly production. The team also analyzes connector orientation cable length and the breakout or bends locations prior to building electronic assemblies. This analysis helps to eliminate budget as well as scheduling problems for many of our OEM customers.

Molded cable assemblies go through our quality control department, where electrical testing process is conducted on all assemblies. To perform such tests, we have a variety of continuity test equipment from Cablescan, P-Tronics and Cirris Electronics. Visual and dimensional inspection, along with intermediate assembly testing, is also performed on request.