Custom Sensor Cable Assembly Manufacturing
Reliable signal transmission solutions for automotive and industrial sensors — overmolded sensor cables, shielded constructions and waterproof exits, engineered as one system and 100 % electrically tested. Custom sensor wiring solutions from a single supplier.
Cross-sections 0.14–1.5 mm²
Lengths 0.3–10 m custom
Sealing IP67 / IP68
Temp −40…+180 °C
Shielding foil · braid · combined
OVERMOLDED SENSOR LEAD · TPU + PUR
OVERMOLDED SENSOR LEAD · TPU + PUR
PORTFOLIO
Sensor cable assembly portfolio
Five recurring assembly families — every one engineered around the signal, the environment and the routing, then built to customer print.
Vibration-proof sensor leads qualified for under-hood temperature and service life.
APPLICATION
Engine · position · pressure sensors
KEY FEATURES
Sealed exits · −40…+125 °C · OEM release
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Sensor-to-controller leads for automation lines — flexible, sealed and clearly marked.
APPLICATION
Automation sensors · control systems
KEY FEATURES
Flexible routing · IP67 · marked leads
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One-piece molded exits fusing connector, seal and strain relief into a single body.
APPLICATION
Washdown · outdoor · mobile machines
KEY FEATURES
Waterproof sealing · strain relief · custom geometry
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Foil and braid constructions that keep low-level analog signals clean to the controller.
APPLICATION
Analog signals · VFD-heavy plants
KEY FEATURES
EMI protection · signal stability · 360° termination
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Customer-specific constructions engineered from the signal spec and routing envelope.
APPLICATION
OEM sensor platforms
KEY FEATURES
Customer-specific design · PPAP support
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APPLICATIONS
Typical applications
Grouped by what the cable must survive - vibration, media, movement and weather. Eachlinks to a dedicated engineering guide as this hub grows.
Under-hood leads that shrug off engine vibration and heat.
Vibration resistance
Temperature durability
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Sensor wiring routed through frames, trays and machine beds.
Flexible routing
Environmental protection
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Leads living in hot oil mist, pressure washers and grime.
Oil resistance
Waterproof protection
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Assemblies exposed to sun, frost and rain for years.
UV resistance
Weather durability
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Clean, traceable sensor wiring for device OEMs.
Reliability
Clean design
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Continuously moving leads that must never fatigue.
Flex life
Torsion resistance
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ANATOMY
Interactive cable assembly anatomy
Select any of the seven layers - the panel shows its function, material and theengineering consideration behind it.
ENGINEERING CHALLENGES
Engineering challenges we solve
Cable programs rarely fail on paper - they fail on noise, moisture and motion. These arethe problems we are hired to remove.
Challenge
Prevent electrical noise and signal loss on the way to the controller.
Solution
Optimized cable construction, twisting and shielding design.
SHIELDED · TWISTED
Challenge
Prevent moisture ingress at the exit and along the jacket.
Solution
Overmolding and sealing design, verified by immersion testing.
IP67 · IP68
Challenge
Maintain performance under repeated movement and routing.
Solution
Proper cable materials and bending radius, engineered per duty.
SHIELDED · TWISTED
Challenge
Prevent cable damage at connection points.
Solution
Integrated strain relief structure molded into the exit.
RIBS ≥ 8 × OD
Challenge
Keep jackets and seals working from deep frost to engine heat.
Solution
Silicone and FEP constructions, validated by thermal cycling.
−40…+180 °C
Challenge
Survive hydraulic oil, coolant and cleaning agents for years.
Solution
TPU and FEP jackets matched to your media list at DFM.
SHIELDED · TWISTED
Challenge
Survive installation pulls and service snags without failure.
Solution
Overmold anchoring and crimp retention, validated by pull-force testing.
REF IEC 60352
Challenge
Join cable and interface without leaks or tolerance conflicts.
Solution
Sealed exits co-engineered with our connector and housing programs.
ONE SUPPLIER
MATERIALS
Cable & material selection
The jacket sets the environment, the shield sets the signal. Compare the options - theconstruction is locked against your duty profile at DFM.
Jacket materials
Shielding options
MANUFACTURING
Cable assembly manufacturing workflow
Seven controlled steps from cut cable to a tested, line-ready assembly - focused on theproduct, not the machinery.
Cut to length, stripped and marked on calibrated automatic lines.
Crimped with force-curve monitoring; crimp height checked per lot.
Terminals seated and secured; seals fitted, position verified by vision.
Conductors dressed, shields terminated 360°, branches taped to drawing.
Low-pressure overmold fuses connector and cable into one sealed body.
100 % continuity and insulation resistance on every assembly.
Dimensions, labeling and pull check per control plan — packed line-ready.
RELIABILITY TESTING
Cable assembly reliability testing
Every assembly is qualified as a signal path - continuity, insulation, sealing andmechanics proven with measured data.
Every conductor verified end-to-end on 100 % of assemblies.
100 % IN-LINE
High-potential and IR verification between all nets and shield.
500 V DC · ≥ 100 MΩ
Crimp and overmold retention pulled to specification per lot.
REF IEC 60352
Immersion and pressure soak on sealed, overmolded exits.
IPX7 / IPX8
Repeated bending at rated radius until the duty cycle is proven.
R = 5–10 × OD
Jacket, seal and overmold stability across thermal extremes.
−40…+125 °C PROFILES
Coverage and 360° shield termination verified on shielded builds.
SHIELD 360° TERMINATED
Automatic electrical test line
Immersion / waterproof rig
Flex & pull test bench
PORTFOLIO
Sensor cable assembly portfolio
Five recurring assembly families — every one engineered around the signal, the environment and the routing, then built to customer print.
Sealing stack, overmold bonding and immersion testing.
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Tool concept, material pairing and geometry rules.
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Foil, braid and 360° termination explained.
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PVC, TPU, silicone and FEP compared by duty.
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Rib geometry, bend radius and exit design.
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Vibration, temperature and OEM release requirements.
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FAQ
Common Questions
Can you manufacture custom sensor cable assemblies?
What cable materials are available?
Can you provide overmolding?
How do you ensure waterproof performance?
Can you integrate connectors and housings?
What industries do you serve?
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Tell Us About Your Part
Send your requirements and a real application engineer will respond within one business day with feedback and pricing.
