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 cable assembly of data cables is crucial for reliable signal transmission and use in demanding environments. High-quality materials such as copper and robust shielding protect against electromagnetic interference. Precisely manufactured plug connections ensure mechanical stability and secure data transmission. Compliance with standards such as ISO/IEC or UL is just as important as careful testing, e.g. through electrical and mechanical tests. Individual adaptations such as cable lengths, color coding or labeling enable tailor-made solutions for your application. Whether for industrial systems, outdoor installations or clean rooms - thanks to detailed coordination between your requirements and production, you benefit from durable, high-performance cable assemblies that provide optimum support for your systems.

High frequency cable

High-frequency or coaxial cables are the ideal choice for transmitting signals at high frequencies, as required in communication technology, measurement technology or broadcasting technology. Thanks to their special construction with inner conductor, dielectric and shielding, they offer excellent signal quality and minimize losses due to electromagnetic interference. The robust shielding also ensures high resistance to external influences. Coaxial cables are available in various impedances, such as 50 or 75 ohms, and can be individually adapted to the requirements of your applications - from flexible variants to rigid versions for permanent installations. Whether for broadband communication, antenna technology or high-precision measurement applications: Coaxial cables stand for reliability and precise signal transmission in critical areas of application.

Energy & power cable

Energy and power cables are essential for the safe and reliable transmission of electrical energy in a wide range of applications. They are used in industry, building technology or mechanical engineering and are designed to withstand high loads. With robust insulation made of PVC, rubber or other materials, they offer protection against mechanical influences, moisture and temperature fluctuations. Depending on the area of application, they are available as flexible or fixed versions and in different cross-sections and voltage ranges. Compliance with standards such as VDE or IEC guarantees safety and quality. Special cable variants are available for special requirements, such as use in potentially explosive areas or under high mechanical stress. Energy/power cables ensure a reliable power supply and offer solutions for versatile and demanding applications.

Hybrid cable

Hybrid cables combine the transmission of power and data in a single cable and therefore offer space and cost-saving solutions for complex applications. They are often used in automation technology, robotics and medical technology, where compact and flexible cabling is required. Thanks to their special design, hybrid cables can meet different requirements, e.g. parallel signal transmission of sensors and actuators as well as the power supply of control units. High-quality materials and optimized shielding ensure interference-free signal transmission and reliable power supply, even under demanding conditions. The option of individual configuration - for example in terms of the number of conductors, cross-sections or connector types - makes hybrid cables the ideal solution for specific requirements. They combine functionality, efficiency and robustness to reliably support even the most demanding applications.

Flat ribbon cable

Ribbon cables are the ideal solution for compact cabling in electronics and automation. Their parallel conductor arrangement enables efficient signal transmission and clean installation. The production of ribbon cables requires the highest precision. One challenge is to keep the conductors exactly parallel in order to avoid signal loss. Insulation displacement technology is often used for the connection, which enables fast and reliable contacting without having to remove the insulation from the conductors beforehand. This technique saves time and ensures long-lasting connections. Ribbon cables are available in various widths and configurations and offer a space-saving, reliable solution for applications with high quality requirements.

Cable harnesses

Cable harnesses bundle several cables into one unit and are indispensable for complex cabling in the automotive industry, aviation, mechanical engineering and medical technology. They ensure order, reduce space requirements and facilitate installation in demanding applications. The production of cable harnesses places high demands: Each cable must be precisely cut, labeled and connected in the right places. The individual configuration of the harnesses requires detailed planning in order to avoid errors. In addition, special connection techniques such as crimp or solder connections are often used. Further attention is paid to the protective sheathing, which protects the cables from abrasion, moisture or chemical influences. Cable harnesses are available in a wide range of variants, from simple bundles to complex systems with connectors and protective sheaths. With a cable harness, you get a tailor-made solution that guarantees reliability and efficiency in your application.

Stranded wires

Stranded wire sets consist of several individually insulated wires (strands) that are bundled into a set and are often used in electrical engineering, medical technology or the automotive industry. They offer a flexible, easy-to-integrate solution for the internal cabling of devices and systems. The production of stranded wire sets requires maximum precision, as each strand must be cut to length, stripped and fitted with connectors, ferrules or soldered connections as required. Crimping technology is often used to create secure and durable connections. The challenges lie in the precise assembly and selection of the right materials to meet specific requirements such as temperature resistance or chemical resistance. Strand sets are often color-coded or labeled for easy integration. Customized strand sets provide you with an efficient, robust and flexible solution for demanding applications.

Overmolding

The overmoulding of cables or connectors using injection molding is a key technology for creating durable, robust and protected connections. This technology is often used in the automotive industry, medical technology and mechanical engineering, where cables and connectors are exposed to high mechanical loads, moisture or chemical influences. During overmoulding, cables and connectors are encased in plastic, which is injected into a mold under pressure. This ensures a firm connection and protects sensitive contact points from external influences. The challenge lies in the precise design to ensure tightness, resilience and accuracy of fit. The choice of material - e.g. PVC, TPU or polyamide - is adapted to the requirements of the application. Overmolded connections not only offer protection, but also improve handling and mechanical stability. They are the ideal solution for applications that require maximum mechanical reliability.

Sensor & actuator cable

Sensor/actuator cables are indispensable for the connection between control systems and field devices. They transmit signals and power reliably, even under harsh conditions such as dirt, moisture or vibrations. With robust sheathing and high-quality workmanship, these cables are specially designed for industrial use. Different variants, e.g. with M8 or M12 connectors, enable easy integration into existing systems. Colored cables and individual lengths simplify installation and maintenance. Sensor/actuator cables stand for precision, durability and reliable transmission - the perfect choice for automation and industrial applications.

Potting

Potting is a proven method of protecting electronic components, cables and plug connections from external influences such as moisture, dirt, vibrations and mechanical stress. This technique is often used in the automotive industry, medical technology and industrial electronics. During potting, a special potting material, such as polyurethane or epoxy resin, is applied to a mold or directly to the components. The material hardens and forms a dense protective layer that insulates the electrical contacts and increases the durability of the components. The challenge with potting lies in the precise dosing and even distribution of the material to ensure a complete seal without air pockets. Potting solutions offer reliable protection, extend the service life of components and are ideal for applications with high demands on robustness and durability.

Trailing chains

Cable carrier assemblies are indispensable for reliable connections between moving machine parts and stationary control systems. They ensure reliable signal and power transmission, even under extreme conditions such as high mechanical loads and frequent bending cycles. With highly flexible cables and robust sheaths, these cables are specially designed for use in drag chains. Precise assembly techniques and individual length adjustments enable optimum integration into your systems. Additional protective measures such as corrugated conduits or braided sleeves increase service life and reliability. Cable assemblies for drag chains stand for durability, precision and reliable transmission - the ideal solution for dynamic industrial applications.

Cable assembly of a high-frequency cable

Miniaturization

Miniaturized cable assemblies are indispensable for use in compact and space-saving applications. They enable reliable signal and power transmission, even in confined spaces and under demanding conditions. The production of these cables requires the highest precision and specialized manufacturing techniques. Fine cables are processed using state-of-the-art machines to ensure consistently high quality. Precise plug connections, often in the micrometer range, are manufactured and assembled using high-precision tools. High-quality materials and careful processing techniques, such as laser welding and microcrimping, ensure a secure and durable connection. Individual length adjustments and different connector types allow flexible integration into your projects. Additional protective measures such as special insulation and potting compounds increase the robustness and reliability of the cables. Miniaturized cable assemblies stand for precision, reliability and space-saving design - 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
Flachleiterkabel
Cable harnesses (Wire Harness)
Hochfrequenzkabel oder Koaxialkabel/Koaxkabel
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 in the development of connection technologies
Fully automatic machines for processing stranded wires, single wire (cutting to length, cutting, stripping, crimping contacts and ferrules, processing sealed contacts, tinning, fitting sleeves, compacting strand ends, splicing and welding, bundling, printing)
Fully automatic machines for cable processing (cutting to length, stripping, winding, printing)
Fully automatic machines for processing flat ribbon cables (cutting to length, cutting, stripping, crimping, punching, splicing, printing)
Stockomats for stranded wires with insulation displacement technology (IDC)
Semi- and fully automatic taping machines
Twisting of strands, stranded wire
Labelling systems (inkjet printing, laser printing, Tampoflex, hot stamping), label printing and automatic winding machines
Crimpers (single contacts, tape) and stripper-crimper machines with crimp force monitoring
Extensive tool portfolio (custom crimping tool procurement available)
Injection moulding machines for the injection - moulding and overmoulding of plugs, connectors, contacts and electronic assemblies or circuit boards for the injection moulding of grommets and the production of components and housings (low pressure: Hotmelt, Macromelt, high pressure: Irogran)
Soldering and fine soldering work, soldering
Laminating machines for processing round cable into ribbon cable
Machines for processing 3M Twinax cables
Ultrasonic welding
Assembly of printed circuit boards
Mechatronic Integrated Devices (MID)
Production 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 machine
Prototype construction with 3D printing
Daisy-chain moulding machines

This is what CiS cable assemblies offer:

Tailored Cable Assemblies – CiS Provides Solutions!

Construction of a cable assembly

To ensure that cables and plug connections fulfil the desired purpose and function reliably, the components must be assembled. This is why both the development and the structure of an assembled cable are so important. Complex cable assemblies are usually first created as a plan on the drawing board before they are produced. This allows various features to be customised during the planning of individual solutions. The following list contains the most important parameters of a cable harness. Depending on the application, these should be taken into account as requirements during planning:

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 different areas

High-quality cable assembly is essential in numerous industries and sectors to ensure smooth operation and optimum performance. In the automotive industry, for example, it is crucial for the reliability of vehicles as it enables a secure and efficient connection between the various electronic components. In the field of telecommunications and information technology, precisely assembled cables are of great importance to ensure fast and reliable data transmission.

Cable assembly also plays an important role in the medical technology sector, as it supports life-saving devices and systems. The energy and automation industries, aerospace and industrial electronics also depend on reliable cable systems to ensure the functionality and safety of their applications. As you can see: In a wide range of industrial sectors, a high-quality cable assembly offers the certainty that the connection technology meets the highest standards and fulfils the increasing 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