Custom cable assemblies: the lifeline of our modern society.

Custom cable assemblies

What are custom cable assemblies? 
Custom cable assemblies are literally the connection points that transmit electrical power, data, and signals between different components. Whether it’s medical equipment saving lives, communication networks connecting the world, or advanced machines controlling production processes, these tailored cables play a crucial role. 

Behind this achievement are engineers and technicians who work with precision and insight to design and manufacture these cables. Each project is unique and requires an understanding of needs, environmental factors, and technological requirements. The result is a network of cables running like veins through our modern society, enabling information and energy to flow and bringing the world around us to life. But how does it work exactly? Let’s take a look at the steps we go through to deliver custom cable assemblies. 

The cable assembly process:

Introduction: The heart of connection 
Our journey begins with an introduction. It’s not just about formal discussions, but about creating a relation with our customers. We want to understand not only their projects but also feel their passion and vision. By listening to their ideas and goals, we can truly put ourselves in their shoes. We understand that it’s about more than just technology. This introduction create the foundation upon which we build further. 

Design and engineering: Smart design, strong connections 
In the design and engineering phase, we work with the customer’s Technical Product Documentation (TPD). While we are not responsible for the initial cable design, we play a crucial role in selecting and optimizing cable assemblies. 

Production and assembly: Creating reliable connections 
Before we start mass-production, we first create a sample for customer approval. Throughout the production process, we ensure quality and consistency through automated crimp centers. Assembly is done carefully, with a focus on quality, safety, and performance. 

Inspection, testing, and quality control: Ensuring perfection 
For custom cable assembly, essential inspection and testing phases are applied to ensure quality. This includes visual inspection for visible damage, continuity tests for uninterrupted connections, insulation tests to prevent leakage currents, pull tests, functional tests for specific tasks, load tests for current capacity, durability tests for realistic conditions, and documentation of materials and results for traceability and quality control. These steps ensure the reliability and performance of custom cables. 

Packaging and shipping: Safely packaged, delivered without worries 
After the cables are carefully assembled according to the specific requirements of the customer, proper packaging is essential to ensure that the cables arrive safely and undamaged at their destination. The packaging must provide not only protection against physical damage but also against moisture, dust, and other environmental factors that could compromise the integrity of the cables. The shipping method, including the choice of carrier and shipping options, plays a role in ensuring timely delivery and customer satisfaction. 

Quality control in cable assemblies: 
We serve as the bridge between customers and suppliers for custom cable assemblies. Quality is at the core of our service and determines the foundation of every project we undertake. We ensure accuracy according to customer requirements and oversee every aspect of production until delivery. Our commitment to quality is affirmed by our compliance with IPC/WHMA-A-620 standards and ISO 9001 & 13485 certifications. Adhering to these standards is both an obligation and a promise to our customers for high-quality cable assemblies that meet the highest standards. We understand that the quality of our products influences the success of customer projects and, therefore, strive to continuously excel. 

The IPC/WHMA-A-620 standard is an industry benchmark specifically addressing acceptance criteria for cable harnesses. It serves as a measure of the quality and reliability of electrical connections and cabling systems. This standard provides detailed guidelines for assembling cables, cable harnesses, and harnesses, imposing strict requirements on aspects such as soldering, crimping, encapsulation, insulation, and labeling. 

ISO 9001 & ISO 13485 certification: 
Both ISO 9001 and ISO 13485 are global quality management system standards. They promote efficient processes and high-quality production. The crucial difference lies in their scope. ISO 9001 contributes to improved internal processes and efficiency, resulting in better products and customer satisfaction. ISO 13485 is specifically focused on medical devices and helps manage risks in all stages of development, resulting in safe and reliable medical products. 

The different types of cable assemblies and their applications:

Our expertise in custom cable assemblies extends to a wide range of possibilities that are precisely tailored to the unique requirements of various industries. From medical equipment to industrial automation, we provide cables that align precisely with our customers’ specific needs. Here are some examples of the application areas we cater to:

Industrial electronics and machinery: These cables are used in various industrial electronics and machinery, ranging from production lines and robotics to measurement equipment and sensor technology. We ensure reliable wiring that meets the industry’s high demands.

Heating pumps and ventilation Systems: Efficiency and reliability play a crucial role in the heating and ventilation sector. These cables and wiring solutions contribute to the proper functioning of climate control systems, ensuring comfortable and healthy living conditions.

Agriculture: The agriculture sector relies on advanced equipment and technologies to increase productivity. These cables support technologies such as precision agriculture equipment and automated irrigation and crop management systems.

Medical: Precision is of the utmost importance in the medical world. We provide cable solutions for medical devices, laboratory equipment, and diagnostic systems, prioritizing safety and consistency.

Maritime: Both commercial and recreational ships depend on electronic systems for navigation, communication, and security. These wiring products withstand the challenging maritime environment and contribute to the reliable operation of these systems.

Energy: Energy production requires robust and sustainable equipment. These cables are used in energy generation systems, including renewable energy sources such as solar panels and wind turbines, as well as in traditional power plants.

A selection of our customers:

Ridder SmartDrive - A motion drive safety system for the agricultural sector

Higosense - Innovative telemedical device for home use

EST-Floattech - The Octopus series is the next generation maritime certified battery system

Outsourcing the benefits of custom cable assemblies without worries:
Our passion is to support you so that you can fully focus on what truly matters: the growth of your business. At Zign Manufacturing, we strive to be your partner in success. We offer our customers the opportunity to have custom cable assemblies taken care of effortlessly at our production facilities, serving as the essential link between our customers and the production locations. 

Furthermore, it leads to significant cost savings. This eliminates the need for internal investments in expensive equipment, training, and personnel. We employ an efficient and streamlined process, leveraging economies of scale and minimizing unnecessary expenses. This results in a strengthened competitive position and greater financial flexibility for our customers. 

Another advantage is access to advanced technologies and materials offered by our locations. Thanks to our collaboration with leading production facilities, we can benefit from the latest innovations in cable technology. This directly translates into higher reliability and improved performance of the cable assemblies we provide.