Molded Cable Assemblies

Consolidated Electronic Wire & Cable proudly offers cable assemblies in a variety of customized styles.

homethumb-molded-cablesOur cable assemblies are designed for both commercial enterprises and consumers, and are used for a wide range of applications such as home electronics, appliances, medical equipment, aerospace, automotive and industrial equipment.

Through nearly a hundred years of service, we have become the industry experts in fabricating custom molded cable assemblies with a range of features such as braiding, terminations, crimping and shrink tubing. molded-cable-assemblyOur offerings also include tinning, soldering, and ultrasonic welding. In addition, Consolidated provides insert and over molding, as well as in-house tooling and assembly.

In addition to providing cables assemblies for home appliances, audio/video and camera link, we also offer braiding, wire-crimping and terminations and cut and shrink tubing.

Our state of the art facilities and manufacturing processes are augmented by our expert staff of technicians and assemblers.

We foster a culture of Total Quality Management, which guarantees that your custom cable assembly will be fully tested, contain the highest quality components and assembled to your exact specifications.

Consolidated Electronic Wire & Cable can meet most electronic requirements, from bulk wire and cable to finished “box builds”, wire harnesses and molded cable assemblies. This helps our customers realize time and cost efficiencies.

Our Customers have recognized the value and benefits of outsourcing their wire and cable requirements to Consolidated and we’ve honed our expertise in areas such as custom cable assembly.

Our cable assemblies are used in a variety of applications ranging from appliances, audio/video, camera link, D-sub, electro-mechanical to medical and automotive.

Consolidated’s more specialized capabilities include braiding, wire-crimping and termination, cut and shrink tubing, ultrasonic welding and tinning and soldering to over- and insert-molding. We also do over-molded tooling, assembly, text fixturing and PCB insertions.

Consolidated offers a wide range of terminals, such as Molex, Amphenol and TE (AMP) terminations as well as spade, fork and ring terminals Consolidated’s engineering team will help select the insulation with properties that best suit the assembly application.

Thanks to our dedicated employees, total quality management system and single-point accountability, we promise to deliver superior quality consistently.

Molded Assemblies Capabilities

Cable Assembly Applications

Appliance Cable Assemblies
Audio/Video
Automotive
Battery
Braided Wire
Business Machines
Box Build
Camera Link
Coax & Coaxial
Coiled
Components
Composite Cable
Custom Molded Connectors
D-Sub Cables
Electromechanical
EMI/RFI Harness
RJ-45 (8-wire)
Flat Molded
Flat Ribbon
Harness & Molded Harness
HDMI & HDMI Mini Molded
IEEE Category 5 & Category 6
LED
Medical Wire
Miniature
Over-Molded Custom
Over-Molded D-Sub Cables with Ferrites
Patch Cords (with Boots/Strain Relief/Flex Relief)
RF Shielded
RFI Shielded
RJ-11 (4 and 6 wire)
RoHS Compliant
SCSI, SAS and SATA
USB (2.0)
USB (3.0)

Custom Capabilities

Copper Wire Braiding
Wire Crimping & Termination
Wire and Cable Prep
Cut & Shrink Tubing
Tywrapping & Lacing
Wire Product Identification
Tinning and Soldering
Ultra Sonic Welding
Cable Assembly Over-Molding
Insert Molding
In-Line

Manufacturing

Over-Molded Tooling
Assembly
Text Fixturing
PCB Insertion

Wire Termination Options

Molex Terminations
Amphenol Terminations
AMP Terminations
Circuit Board Ready
Spade Terminals
Fork Terminals
Ring Terminals
Hard Wired
LED
Light Sockets
Molded
Overmolded
Metal Formed
Plastic Injection Molding
Tinned
Soldered
Switches
Stripped and Tinned
Ultra Sonic Welding
Crimped Ends

Insulation Materials

PVC - Polyvinyl Chloride
SR-PVC - Semi Rigid Polyvinyl Chloride
Cellular Polyethylene
EPDM - Ethylene Propylene Diene Monomer
TPE/TPR - Thermoplastic Elastomers
PE - Polyethylene
LDPE - Low Density Polyethylene
HDPE - High Density Polyethylene
Cellular (Foam) Polyethylene
PU - Polyurethane
Polyurethane / Nylon
Low Smoke Plenum Co-Polymers / PVC
PP - Polypropylene
Cellular (Foam) Polypropylene
FEP - Fluorinated Ethylene Propylene
TFE - Tetrafluoroethylene
PTFE - Polytetrafluoroethylene
ETFE Tefzel
PVDF Kynar
ECTFE Halar
IRR/PVC - Irradiated Polyvinyl Chloride
XLPE - Cross-Linked Polyethylene
Vinyl (PVC)
And many others

Conductor Materials

Bare Copper Wire
Tinned Copper Wire
Silver Plated Copper Wire
Nickel Plated Copper Wire
Copperweld/Copper Covered Steel

Voltage

Up to 600 V (UL)
3000 V (Military)

Temperature Range

-65ºC to 250ºC

Conductor Gauge

4 to 40 AWG

Conductor Cabling

1 Conductor to 60 pairs

Stranding Constructions

Solid
Bunched
True Concentric
Rope Lay

Conductor Coatings

Tinned Copper
Heavy Tinned Copper
Prefused Copper
Overcoat Copper
Top Coated Copper
Silver Plated Copper
Nickel Plated Copper

Shielding

Braided Wire
EMI/RFI Shielding
Mylar/Aluminum Foil
Mylar/Aluminum Foil + Braid
Spiral Serve Wire

Cable Filler

Polypropylene
Nylon
Paper

Quality Assurance

Consolidated Total Quality Mangement

Quality Control

Single Point Accountability

Testing

Standard UL, CSA & Industry Testing Procedures
Custom Testing Parameters Available Upon Request

Production Volume

100 Units to OEM Volumes

Typical Lead Time

3 Weeks to 10 Weeks

Additional Information

Industry Focus

Aerospace
Agriculture
Amusement
Appliances
Automotive
Broadcast
Commercial
Communications
Computer
Factory Automation
Gaming
Home Entertainment
Local Utilities
Marine
Medical
Military
Power Supply
Public Safety & Transportation
Renewable Energy
Robotics
Security
Solar Power Energy
Telecommunications
Wind Power Energy
Wireless
Industrial Machinery

Industry Standards & Approvals

ISO 9001
QS 9000
RoHS Compliant
CE
CSA
C-UL
HAR
Automotive J-1128
UL
NEC
VDE
OSHA
Category 5/6/7
Lead Free

File Formats

CAD Capabilities
DWG
PDF
.PPT
.XLS/.XLSX
.DOC/.DOCX