The Complete Guide to OEM Cable Assembly

Cars, industrial machinery, medical devices, and other modern electronics rely on wiring to transmit data, power, and signals between internal components and external peripherals. This wiring must be custom-built using OEM cable assemblies to ensure maximum reliability, safety, and performance. 

This guide covers cable assembly organization options and key factors when selecting a contract manufacturer.

What Is an OEM Cable Assembly?

Original Equipment Manufacturer (OEM) parts are components produced by the same company that designs and builds the final product, rather than by a third-party supplier or subsidiary.

An OEM cable assembly is a custom-built wiring harness or cable bundle designed for a specific piece of equipment. These assemblies support specialized functions across different device sections, ensuring efficient data transmission, power, or signals.

OEMs Across Different Industries

Automotive

Modern vehicle communication and safety systems need cable assemblies that meet strict performance standards for durability, vibration resistance, and high-temperature resistance.

Telecommunications

Cable assemblies help build robust network infrastructures in communication towers and data centers. They also enable reliable, high-speed data transmission in networking equipment.

Medical

Cable assemblies in the medical field must adhere to stringent health and safety standards to ensure reliability and biocompatibility in diagnostic equipment, patient monitoring systems, portable/handheld medical devices, implants, etc.

Aerospace

Aerospace demands reliable real-time communication, navigation, and instrumentation, making Cable assemblies necessary because they maintain optimal performance despite exposure to extreme conditions.

Industrial

Cable assemblies are built to ensure these systems transmit data and signals reliably despite being exposed to extreme heat, chemicals, and physical wear.

Renewable energy 

Renewable energy systems like solar rely on cable assemblies to ensure consistent power delivery while withstanding harsh environmental conditions, including UV exposure, extreme temperatures, moisture, and corrosion.

Agriculture

Like industrial applications, agriculture is becoming more automated, meaning reliable real-time data transmission is paramount. For instance, tractors need real-time GPS data transmission to navigate the fields when ploughing.

Oil and Gas

Cable assemblies for this field are built to withstand chemicals and fire exposure, which ensures operations run smoothly even when mishaps occur.

Military and Defense

This category combines several advanced fields, such as communications and aerospace, with more demanding requirements. Cable assemblies used in military and defense applications, including aircraft, communication networks, and early detection systems, must deliver exceptional reliability, performance, and durability under extreme operating conditions.

Why Use an OEM Cable Assembly?

Although costlier than their generic counterparts, OEM cable assemblies are important for the following reasons.

Factory Certified and Guaranteed

Building cable assemblies requires the original manufacturer’s blueprints or specifications. This ensures the final product is plug-and-play and meets performance standards.

Safety

OEM cable assemblies are custom-built with safety features tailored to their specific functions. They help ensure systems operate reliably and can provide feedback when needed.

For instance, a generic battery cable assembly in a vehicle can only channel power to the electronics. But its OEM counterpart has features like fusible links for circuit protection or an EBS on the terminal to measure the battery’s temperature and voltage.

Performance in OEM Equipment Engineering

In ICE vehicles, OEM cable assemblies provide reliable real-time data transmission from various sensors in the engine and transmission to ensure efficient operation and better driving dynamics.

Cable Assembly Customization Options

Cable assemblies include wires, cables, terminals, connectors, and harnesses for specialized functions. 

Wires/Cables

The most suitable wire to use depends on several factors, which include:

• Application type: GPT/GXL/SXL for automotive, high-resistance wire, high-temperature wire, etc.
• Wire gauge: Should match the AWG standard without cheating by using thick insulation.
• Wire color: Color dies on white insulation can come off, so the best solution is to use solid-color extrusion insulation.
• Wire stripping color: Can be white, colored, or cross-colored.
• Wire and strip length: Matches the specific application.
• Insulation material type: The best insulation that maximizes durability is petroleum-based (PVC and XLPE). We avoid soy-based insulation due to rodent attraction.
• Origin: For quality purposes, only go for wires built by reputable manufacturers in the industry.

Terminals/ Connectors

We pick the matching terminals/connector type for each harness according to the OEM specifications or replace them if they are obsolete. We are also careful enough to match the connector color and material.

Lamp Sockets

We look at the design, material, and functionality for 100% matching for bulb sockets.

Grommets

The factors to consider are the grommet size, durometer, material, orientation, and color.

Clips & Clamps

Some customization options for the clip and clamp are their type, durometer, color, material, orientation, and placement.

Tape

We consider the tape color, width, type (cloth, fiberglass for high-temperature areas, adhesive, or non-adhesive), and wrapping to match the OEM cable assemblies. We also use automated machine taping to ensure uniform spacing, overlapping, and tightness.

What to Look for in an OEM Cable Assembly Manufacturer

Online Cable Assembly Configurator

An online configurator allows you to design custom OEM cable assemblies from scratch by picking components or parameters for each part. These include the cable types, materials, connectors, wire length, etc. 

The more customization options on the configurator, the more accurate the pricing estimation will be before you place an order, and the better the specification details will be provided to the manufacturer for quicker and precise production.

Parts Sourcing Capability for OEMs

Sourcing expertise is critical in this line of business because it affects production timelines, product quality, budget, and correctness. Your contract manufacturer should have a dedicated sourcing department comprising experts plus deep networks with reputable suppliers.

At Wiringo, we have built networks with quality component manufacturers to keep our supply chain as efficient as possible. But we don’t just transfer these components to our stock rooms when they arrive. They are checked against the BOM and inspected thoroughly for quality and correctness to match the required part numbers.

Advanced Manufacturing Techniques 

If the original parts have become obsolete, the contract manufacturer is supposed to have the tooling required to rebuild them according to OEM specifications. 

For example, to create the wire joint, we machine-crimp them using a 3–5 ton press and dip-solder if necessary before testing random samples using digital pull-testing machines for quality control.

Industry Certifications

OEM cable assemblies should follow established industry standards, which means your contract manufacturer must hold the appropriate certifications. Key examples include IATF 16949 for automotive quality, ISO 9001 for general quality management, and ISO 14001 for environmental compliance.

We use automated machines and robotics to streamline manufacturing and assembly, speeding up production and minimizing human error. Every step of the process is carried out with strict adherence to industry standards.

Flexible Order Quantities

Your manufacturer should offer flexible order quantities that can be adjusted based on customer demand, without significant price increases or penalties. This flexibility is important for meeting changing business needs.

We support both low and high-volume orders. Larger orders benefit from economies of scale, but smaller orders are still priced competitively. We can adjust these details and compare pricing with our cable assembly configurator.

On-Time Delivery

Product delivery on schedule will reduce customer frustrations and improve profitability and competitiveness. To check on this, ensure your manufacturer has an efficient production process, supply chain, and shipping option(s).

Our lead times are short. This is complemented by our fast shipping options globally.

Warranty

While quality control is important, you should only choose a manufacturer that offers a product warranty. This protects your business from potential financial losses caused by malfunctions or manufacturing defects.

Choose Wiringo as Your Manufacturer

OEM cable assemblies are pricier than the ones available in the gray market, but that reflects their quality and reliability.

Wiringo’s cable assemblies qualify as OEM because they are built to exact original specifications using factory blueprints. Each assembly is a precise plug-and-play reproduction, fully assembled, factory-correct, and ready to install.

Contact us to get started on your order or to get a free quote.