Cable Assembly

DesignCore Systems designs and manufactures custom cable assemblies and wiring harnesses to support the delivery of our systems, as well as providing rapid prototyping, modification, replacement, and repair solutions for customer cable requirements. From initial design through to production and rework, we deliver reliable, application-specific cabling solutions tailored to meet project and operational needs.

Our manufacturing process covers connector selection and crimping, cable routing, sleeving, labelling, and continuity testing. We work with a broad range of connector families including circular military-spec, M12, M8, D-Sub, USB, and custom-pinout variants. Assemblies are produced to IPC/WHMA-A-620 workmanship standards.

From prototype single-units through to small production runs, we provide documentation packages including cable schedules, connector pinout drawings, and test records. Assemblies can be supplied loose or integrated into enclosures and equipment builds.

Help

Frequently Asked Questions

What types of cables and connectors do you work with?
We work with a wide range of cable types including screened signal, power, coaxial, data (Cat6/Cat6A), and specialty industrial cables. Connector families include circular (MIL-DTL-38999, M12, M8), rectangular (D-Sub, MIL-DTL-24308), USB, RJ45, and custom configurations. If your application requires an uncommon connector type, contact us and we will advise on sourcing and compatibility.
What is the minimum order quantity?
We manufacture from a single prototype unit. There is no minimum order quantity — we understand that engineering projects often require one-off assemblies for development and testing before committing to a production run. Unit pricing reflects the quantity ordered, and we are happy to discuss volume pricing for repeat orders.
What are your typical lead times?
Lead time depends on component availability and assembly complexity. Simple assemblies using in-stock connectors and cable can often be completed within 3–5 business days. Complex harnesses with long lead-time components typically require 2–4 weeks. We will confirm lead time as part of the quoting process once we have reviewed your requirements.
What cable test solutions can you offer?
We provide manual and automated cable test solutions to support cable assembly validation, fault finding, and production testing. Our tailored solutions deliver accurate, repeatable testing for continuity, insulation, wiring integrity, and electrical performance.

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