Printed Circuit Board Assembly

A PCB cable assembly is a collection of cables designed for use with printed circuit boards. It comprises a group of 2 or more conductors bundled together and encased in a protective covering. The ends feature connectors or terminations, whose design can vary depending on the usage requirements.

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PCB Cable Assembly Manufacturing

Our connected world has increased in technological advancements at an exponential rate and the need for both commercial and industrial PCBs has risen in lockstep. Not only do PCBs and cable harness assemblies need to be highly capable but getting these products into the hands of clients given the many supply chain restrictions seen today takes a proven supply chain management system in place.

At Meridian, we deliver these kinds of exceptional results every day with a full line of some of the most advanced manufacturing capabilities available. From prototyping runs to making sure every component comes together perfectly to massive volume manufacturing, PCB assembly along with the custom cable assemblies provides total box, as well as sub-assembly set-ups for even the most challenging circumstances.

PCB assembly can take many different shapes, depending on the needs of the project. There’s flex PCBs and standard rigid boards, single boards, double boards, multiple layers, and even specialized aspects like through-hole printed circuit boards. All of these require a perfect set of design parameters and precise engineering to provide a useful final product that will easily integrate into its intended system.

What are the Advantages of PCB Cable Assemblies?

It Simplifies the PCB Assembly

Cables are less challenging to produce and use than designing connections and soldering components on a circuit board. Using them simplifies the PCB assembly process by reducing the work the fabricator has to perform on the board.

Reduced PCB Manufacturing Costs

With the simplified PCB design and assembly steps, you reduce the cost of manufacturing your circuit boards when using wire connections. The cost savings become significant if you’re mass-producing the PCBs for your project.

Increased PCB Adaptability

By allowing connection with external devices or systems, the assembly increases the circuit board’s versatility and usable in a broad range of applications. It also makes connections more straightforward, allowing modifications to meet future usage needs.

Enhanced Safety and Durability

The assembly has a plastic or rubber covering. The insulating properties of the sleeve make the conductors safe to work with. It also offers protection against environmental damage, increasing the lifespan of the assembly and the circuit board.

What is a PCB Cable assembly Made Of?

Conducting Wires

Typically made from copper, the conducting wires transmit information or voltage from one point to another. They must have the correct rating for current carrying capacity. They are also available in different diameters based on the usage needs.

Outer Covering/Sheath

The sheath covers the wires. It can be different materials. Options for the covering include extruded or shrink-wrapped thermoplastic, vinyl, or even rubber. The material must resist damage from abrasion, moisture, heat, and other conditions.

Insulation

The insulation here refers to the material covering the individual wires in the assembly. Its function is to protect the wires from shorts or mechanical stress. It ensures the product serves its purpose reliably without experiencing dielectric breakdown and other problems.

EMI Shielding

The EMI shield is an optional part. It’s only necessary when the application requires one, such as if the PCB and cable operate in a radiation-prone environment or carry RF signals. It’s usually a sheath made of braided wires and a thin foil surrounding the wire or wires.

Connectors or Terminations

The ends of the assembly connect to the circuit board or other device using connectors or terminals. Different connector types or coupling mechanisms are available. They include insulation-displacement, wire-to-wire, wire-to-board, and screw connections.

Understanding the Printed Circuit Board Assembly Manufacturing Process

The custom cable manufacturing process consists of four main stages

Design. In the design phase, designers and engineers work closely with customers to outline their needs and constraints. These requirements and restrictions are used to create and digitally test potential designs.
Prototyping. In the prototyping phase, physical models of potential cable assembly designs are created. These units are used to test for functionality and manufacturability, ensuring they can be made and used as intended.
Production and Assembly. In the production and assembly phase, the cable assemblies are manufactured as per the approved final design in the desired volumes. The manufacturing process consists of many steps, including cutting the conductors, establishing their connections, and assembling them into a single wrapped jacket.
Testing. In the testing phase, the completed assemblies undergo rigorous testing to ensure they perform safely and effectively. The exact tests depend on industry and application requirements.

At Inno Cables have been manufacturing Printed Circuit Board Assembly for 15 years.

Driven by our expert production operators; Inno Cables has manufactured Printed Circuit Board Assembly for the following industries:

Computer and computer installations
Panel displays
Lighting systems
Automotive systems
Surveillance and navigation
Manufacturing equipment and machinery
Robotic systems
Telecommunication equipment
Aerospace electronics

At Inno Cables we go above and beyond to guarantee the quality of our Printed Circuit Board Assembly:

Bespoke Electrical & Directional Testing Service
Final Quality Control Checks

We offer the following Printed Circuit Board Assembly services:

Design Improvements
Sourcing of Material
Prototyping
Test
Kitting

Standards

IPC/WHMA-A-620

Our Advantages

Flexibility

We are able to provide customized solutions to meet your specific requirements, including unique designs, materials and configurations.

Quality

We are committed to providing the highest quality cables and wire assemblies, and we only use the best materials and manufacturing processes to ensure that our products meet the highest standards.

Standards

Cables are subject to stringent standards that determine how they are designed, manufactured, and installed. A good partner should be well-versed in all of the required and recommended guidelines.

Speed

Our rapid prototyping and manufacturing capabilities enable us to quickly deliver your custom cable or wire assembly, thereby reducing your time to market and helping you stay ahead of the competition.

Competitive Pricing

Our efficient manufacturing processes and bulk purchasing capabilities enable us to offer competitive pricing without sacrificing quality.

Customer Service

Our dedicated team of professionals is committed to providing excellent customer service and support, and we are always available to answer your questions and solve your problems.

If you have any questions?

If you have any inquiries or need more information about our wire harness products and services, please feel free to contact us.