CiS produces high-quality customized cable assemblies, component assemblies and electromechanical components. Experienced, competent, and motivated employees, along with modern machinery , ensure commercially and technically optimized solutions. Small, medium, and large production series in connection technology are manufactured to the highest quality standards and supported by a supply chain management system.

Cable Assembly by CiS – Fast & Reliable

What Is Cable Assembly?

A pre-assembled cable, cable set, or cable assembly consists of either a simple A-to-B connection or a complex wiring harness. A wiring harness consists of multiple strands and/or cables. Large cable harnesses can contain several hundred, or even thousands, of contact points. A cable harness is a fundamental component of electrical power and data transmission in almost all technical devices and systems. Every cable system must operate reliably for years, sometimes under adverse conditions, to ensure the customer's electrical system remains functional.

Cable assembly is the process of producing a ready-to-connect cable set with connectors. In addition to cables, cable bundles, cable sets, and complete cable harnesses can be assembled. A complete assembly includes the installation of plugs, connectors, ferrules, and contacts. Ready-to-connect cables are used in industrial processes where energy or data is electronically transmitted. Depending on the specific purpose, special cables and connectors must be selected for the cable assembly.Cable assemblies can be either standardised or customised. The requirements of customers needing customised cable assemblies can typically be met. Please do not hesitate to contact our experts!

However, cable assemblies also differ in several aspects. High-speed data transmissions are susceptible to interference, which is why cables and connectors are shielded accordingly. In the case of power transmission, safety, electromagnetic compatibility and the reduction of losses take centre stage. For power transmission, safety, electromagnetic compatibility, and loss reduction are the main priorities. These varying requirements directly influence the selection of stranded wires, cables, and connectors.

How Does the Cable Assembly Process Work?

The production of a pre-assembled cable harness is usually automated for standardised solutions. These are produced in high volumes. The machine automatically assembles individual components, such as cable connectors, contacts, and ferrules. For customised cable assemblies and special applications, cable and connector designs are often highly specialised and complex. This requires a manufacturing process that integrates semi-automated and manual production steps.

Crimping
Soldering
Cutting and clamping (IDC)
Ultrasonic welding / ultrasonic compacting
Overmolding

What Are the Benefits of Customized Cable Assemblies?

Precision Fit: Customised cable assemblies are designed to meet the exact requirements of a specific application, ensuring a perfect fit and superior performance compared to standard cables..
Reliability: Customised cable assemblies are engineered for specific requirements, ensuring optimal performance and increased reliability compared to standard cables.
Flexibility: Customised cable assemblies are designed for specific applications, making them suitable for diverse environments.

What Are the Requirements for Cable Assemblies, and What Should Be Considered During Assembly?

Cable assembly is essential because it enables the creation of customised cables that meet the exact requirements of a specific application. These customised cables are more efficient and reliable than standard cables because they are specifically designed for a particular application. This guarantees safe, reliable, and efficient transmission of data and power between components.

1. Preventing Power Failures

A poorly constructed cable assembly can result in power failures, potentially causing significant damage to electronic devices. A well-designed cable harness minimises this risk, ensuring reliable device operation.

2. Improved Data Transmission

A well-designed cable assembly optimises data transmission between components. This is especially important for devices that require fast and reliable data exchange.

3. Increased Efficiency

A well-designed cable assembly enhances the efficiency of electronic devices by optimising power and data transmission. This can extend the lifespan of devices and help reduce operating costs.

4. Enhanced Safety

Improper cable assembly can cause short circuits, overheating, or even fires, posing a serious risk. A well-engineered cable assembly minimises safety risks, ensuring secure and reliable operation.

What Should Be Considered When Designing a Cable Assembly?

When designing a cable assembly, several factors must be considered to ensure safety, reliability, and efficiency. Below are some key aspects to consider:

1. Materials

Selecting the right materials for cable assembly is crucial. Materials should meet specific application requirements and ensure a long service life. Additionally, they should be resistant to chemicals and moisture to enhance reliability and durability.

2. Wiring and Connectivity

Wiring and connectivity must be carefully executed to ensure optimal power and data transmission. Proper connections and shielding also minimize noise and interference.

3. Strain relief

Adequate strain relief is essential to prevent cable damage and maintain a secure connection. It should provide both stability and flexibility to withstand mechanical stresses.

4. Coding

Cable assemblies should be coded for easy identification and seamless component integration. Proper coding also simplifies troubleshooting and reduces the risk of connection errors.

5. Testing and Quality Control

Cable assemblies must undergo rigorous testing and quality control to ensure compliance with requirements. Testing and quality control guarantee that the cable assembly remains safe, reliable, and efficient.

What Factors Should Be Considered When Selecting the Right Cable Manufacturer?

1. Experience

Experience in the development and manufacture of cable assemblies is particularly important in order to customise the cable assembly to the requirements of your specific industry. With over 45 years of experience and know-how, we can implement any type of customised requirements in your industry. We can bring experience from a wide range of industries to your product and optimise it, taking into account the total cost of ownership.

2. Quality

Check that the service provider uses high-quality components and carries out the cable assembly process carefully to ensure that the cable will function smoothly. CiS stands for the highest quality without exception. Our cable assemblies go into life support. Our processes are ISO 9001 certified.

3. Customer Support

When it comes to customised solutions, good customer support is crucial to finding a targeted solution and responding quickly to your requirements.

As one of the most experienced cable assembly companies on the market, CiS has also perfected these factors over the years. Quality, reliability and customer service go hand in hand and are our top priority. We offer an uncomplicated and smooth process so that you can focus entirely on your core processes. CiS solves tasks!

Connecting the World with Our Cable Assemblies

Data Cable

The assembly of data cables is essential for reliable signal transmission, particularly in demanding environments. High-quality materials, such as copper conductors and robust shielding, protect against electromagnetic interference (EMI). Precisely manufactured connector interfaces ensure mechanical stability and secure data transmission. Compliance with industry standards such as ISO/IEC or UL is just as crucial as rigorous testing, including electrical and mechanical assessments. Custom adaptations—such as specific cable lengths, color coding, and labeling—allow for tailor-made solutions for your application. Whether for industrial systems, outdoor installations, or cleanroom environments—thanks to meticulous coordination between your requirements and production—you benefit from durable, high-performance cable assemblies that optimally support your systems.

High Frequency Cable

High-frequency or coaxial cables are ideal for transmitting signals at high frequencies, as required in communication, measurement, or broadcasting technology. Thanks to their specialized construction with an inner conductor, dielectric, and shielding, they offer excellent signal quality and minimize losses caused by electromagnetic interference (EMI). The robust shielding provides high resistance to external influences. Coaxial cables are available in different impedance values, such as 50 or 75 ohms, and can be customized to meet your specific application requirements—from flexible designs to rigid versions for permanent installations. Whether for broadband communication, antenna technology, or high-precision measurement applications, coaxial cables ensure reliability and precise signal transmission in critical applications.

Energy & Power Cable

Energy and power cables are crucial for the safe and reliable transmission of electrical energy across various applications. They are used in industry, building technology, and mechanical engineering and are designed to withstand high loads. Featuring robust insulation made of PVC, rubber, or other materials, they provide protection against mechanical stress, moisture, and temperature fluctuations. Depending on the application, they are available in flexible or fixed versions and in various cross-sections and voltage ranges. Adherence to standards such as VDE and IEC ensures safety and quality. Special cable variants are designed for demanding applications, such as use in potentially explosive environments or under extreme mechanical stress. Energy and power cables ensure a reliable power supply and provide solutions for versatile and demanding applications.

Hybrid Cable

Hybrid cables integrate power and data transmission in a single cable, providing space- and cost-saving solutions for complex applications. They are frequently used in automation, robotics, and medical technology, where compact and flexible cabling is essential. Due to their specialized design, hybrid cables can meet various requirements, such as parallel signal transmission for sensors and actuators, as well as power supply for control units. High-quality materials and optimized shielding enable interference-free signal transmission and a reliable power supply, even under demanding conditions. The ability to customize hybrid cables—for example, in terms of the number of conductors, cross-sections, or connector types—makes them the ideal solution for specific requirements. They combine functionality, efficiency, and robustness to reliably support even the most demanding applications.

Flat Ribbon Cable

Flat ribbon cables provide an ideal solution for compact cabling in electronics and automation. Their parallel conductor arrangement ensures efficient signal transmission and a tidy installation. Manufacturing ribbon cables requires utmost precision. A key challenge is maintaining precise conductor alignment to prevent signal loss. Insulation displacement technology is commonly used for connections, allowing fast and reliable contacting without the need to strip the insulation beforehand. This method saves time and guarantees durable connections. Ribbon cables are available in various widths and configurations, providing a space-saving and reliable solution for high-quality applications.

Cable Harnesses

Cable harnesses bundle multiple cables into a single unit and are essential for complex cabling in the automotive, aviation, mechanical engineering, and medical technology industries. They ensure organization, reduce space requirements, and simplify installation in demanding applications. Manufacturing cable harnesses involves high precision: Each cable must be accurately cut, labeled, and connected at the designated points. Custom configuration of harnesses requires detailed planning to prevent errors. Additionally, specialized connection techniques, such as crimping or soldering, are frequently employed. Particular attention is given to the protective sheathing, which safeguards the cables from abrasion, moisture, or chemical exposure. Cable harnesses come in a variety of configurations, ranging from simple bundles to complex systems with connectors and protective sheathing. A cable harness provides a tailored solution that ensures reliability and efficiency in your application.

Stranded Wires

Stranded wire sets consist of multiple individually insulated wires (strands) bundled into a set and are commonly used in electrical engineering, medical technology, and the automotive industry. They provide a flexible, easy-to-integrate solution for internal device and system cabling. Manufacturing stranded wire sets demands the highest precision, as each strand must be cut to length, stripped, and fitted with connectors, ferrules, or soldered connections as needed. Crimping technology is frequently employed to establish secure and long-lasting connections. Challenges include precise assembly and selecting the appropriate materials to meet specific requirements, such as temperature and chemical resistance. Stranded wire sets are typically color-coded or labeled for seamless integration. Customized stranded wire sets offer an efficient, robust, and flexible solution for demanding applications.

Overmolding

Overmoulding cables or connectors using injection molding is a key technology for creating durable, robust, and protected connections. This technology is widely used in the automotive, medical, and mechanical engineering industries, where cables and connectors are exposed to high mechanical loads, moisture, or chemical influences. During overmoulding, cables and connectors are encapsulated in plastic, which is injected into a mold under pressure. This process ensures a secure connection and shields sensitive contact points from external influences. The challenge lies in precise design to ensure tightness, resilience, and accuracy of fit. The choice of material—e.g., PVC, TPU, or polyamide—is tailored to the specific application requirements. Overmoulded connections not only provide protection but also enhance handling and mechanical stability. They are the optimal solution for applications requiring maximum mechanical reliability.

Sensor & Actuator Cable

Sensor and actuator cables are indispensable for connecting control systems and field devices. They reliably transmit signals and power, even under harsh conditions such as dirt, moisture, or vibrations. Featuring robust sheathing and high-quality workmanship, these cables are specifically designed for industrial applications. Various versions, such as those with M8 or M12 connectors, allow for easy integration into existing systems. Color-coded cables and custom lengths simplify installation and maintenance. Sensor and actuator cables represent precision, durability, and reliable transmission—making them the perfect choice for automation and industrial applications.

Potting

Potting is a well-established method for protecting electronic components, cables, and connectors from external influences such as moisture, dirt, vibrations, and mechanical stress. This technique is commonly used in the automotive industry, medical technology, and industrial electronics. During potting, a specialized potting material, such as polyurethane or epoxy resin, is applied to a mold or directly onto the components. The material hardens and forms a solid protective layer that insulates the electrical contacts and enhances the durability of the components. The challenge in potting lies in precise dosing and even distribution of the material to ensure a complete seal without air pockets. Potting solutions provide reliable protection, extend the service life of components, and are ideal for applications requiring high robustness and durability.

Trailing Chains

Cable carrier assemblies are essential for ensuring reliable connections between moving machine parts and stationary control systems. They guarantee reliable signal and power transmission, even under extreme conditions such as high mechanical stress and frequent bending cycles. Equipped with highly flexible cables and durable sheaths, these cable assemblies are specifically designed for use in drag chains. Precision assembly techniques and customized length adjustments allow for optimal integration into your systems. Additional protective measures, such as corrugated conduits or braided sleeves, extend service life and enhance reliability. Drag chain cable assemblies represent durability, precision, and reliable transmission—making them the ideal solution for dynamic industrial applications.

Cable assembly of a high-frequency cable

Miniaturization

Miniaturized cable assemblies are essential for compact and space-saving applications. They ensure reliable signal and power transmission, even in tight spaces and under demanding conditions. Manufacturing these cables demands the highest precision and specialized techniques. Delicate cables are processed with state-of-the-art machinery to guarantee consistently high quality. Precision connectors, often in the micrometer range, are manufactured and assembled with high-precision tools. High-quality materials and meticulous processing techniques, such as laser welding and microcrimping, guarantee a secure and long-lasting connection. Custom length adjustments and various connector types enable flexible integration into your projects. Additional protective measures, such as specialized insulation and potting compounds, enhance the robustness and reliability of the cables. Miniaturized cable assemblies embody precision, reliability, and a space-saving design—making them the perfect choice for modern, compact applications.

What Types of Cables Exist?

Copper cable accessories
Assemblies for fibre optic cables or glass fibre
Round Cable
Motor encoder cables
Flat Ribbon Cable
Flat conductor cable
Cable Harnesses (Wire Harness)
High-frequency cable or coaxial cable/coaxial cable
Twinax cable (high-speed data transmission)
Signalling cable or power cable
Connecting cables
High-Voltage Cable

What Makes CiS the Best Choice for Cable Assemblies?

Support for the development of connection technologies
Fully automatic machines for processing stranded and single wires (cutting to length, stripping, crimping contacts and ferrules, processing sealed contacts, tinning, fitting sleeves, compacting strand ends, splicing, welding, bundling, and printing)
Fully automatic machines for cable processing (cutting to length, stripping, winding, printing)
Fully automatic machines for processing flat ribbon cables (cutting to length, stripping, crimping, punching, splicing, printing)
Stockomats for stranded wires with insulation displacement technology (IDC)
Semi-automatic and fully automatic taping machines
Twisting of strands and stranded wires
Labelling systems (inkjet printing, laser printing, Tampoflex, hot stamping), label printing and automatic winding machines
Crimping machines (single contacts, tape) and stripper-crimper machines with crimp force monitoring
Extensive tool portfolio (custom crimping tool procurement upon request)
Injection moulding machines for injection moulding and overmoulding of plugs, connectors, contacts and electronic assemblies or circuit boards. These machines also enable injection moulding of grommets and the production of components and housings (low-pressure: Hotmelt, Macromelt, high-pressure: Irogran).
Soldering and fine soldering work
Laminating machines for converting round cables into ribbon cables
Machines for processing 3M Twinax cables
Ultrasonic welding
Printed circuit board (PCB) assembly
Mechatronic Integrated Devices (MID)
Manufacturing of sensors (capacitive, inductive, thermal)
Component assembly, including control cabinet and system assembly
Test adapters and digital test systems
Plastic injection moulding machines
CNC machines
Bolting machines
Prototyping with 3D printing technology
Daisy-chain moulding machines

What CiS Cable Assemblies Provide:

Tailored Cable Assemblies – CiS Provides Solutions!

Construction of a Cable Assembly

To ensure that cables and plug connections function reliably and serve their intended purpose, all components must be correctly assembled. Therefore, both the design and structure of a cable assembly are crucial. Complex cable assemblies are typically designed on a drawing board before moving into production. This enables customization of various features during the planning of tailored solutions. The following key parameters of a cable harness should be considered during the planning phase, depending on the application:

Voltages / currents of the application
Interference, fastening, cable insulation, length and weight
Protection against moisture, impacts and temperatures (heat and/or cold)
Mechanical stress and bending radius of the cables

Cable Assembly: Customized Solutions for Various Industries

High-quality cable assembly is essential across various industries to ensure seamless operation and optimal performance. In the automotive industry, for example, it plays a crucial role in vehicle reliability by ensuring secure and efficient connections between electronic components. In telecommunications and information technology, precisely assembled cables are vital for fast and reliable data transmission.

Cable assembly is also critical in medical technology, supporting life-saving devices and systems. The energy and automation industries, as well as aerospace and industrial electronics, rely on reliable cable systems to guarantee functionality and safety. As evident, high-quality cable assembly is indispensable across various industries, ensuring that connection technology meets the highest standards and the evolving demands of our modern world.

Products, That Set New Standards

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Your Direct Connection to Us - Personal and Competent!

At CiS, you and your requirements take center stage. With customized solutions and deep technical expertise, we support you in turning your ideas into reality. Our experienced team is at your side in every phase of your project - from the initial consultation to development and series production.

Do you have a challenge for us? Then please do not hesitate to get in touch. Connections are built on trust – and that's our foundation.

Our team is always happy to assist you.

Daniel ThormählenCustomer Onboarding Manager

+49 2151 3787 0

rfq@cis.de

Europark Fichtenhain A15 
47807 Krefeld 
Germany