Customized Cable Assemblies

Cable Assemblies

Custom Cable Assemblies

Winchester Electronics specializes in High Mix / Low volume cable assemblies, which are designed and manufactured within the company’s global footprint:

Winchester utilizes an open-source connector policy for its cable assemblies using KINGS, Cadillac, Continental, and Winchester brands of connectors; or connectors from any other manufacturer that meets the requirements of the customer’s cable assembly requirements. Winchester Electronics is solely focused on providing the best product solution.

The Winchester engineering team will support you as little or as much as you need to develop and finalize your product’s design and manufacturing drawings, including:

  • Reviewing customer supplied drawings to ensure that the cable assemblies and wire harnesses meet Winchester Electronics’ Designed-For Manufacturability (DFM) requirements.
  • Reverse-engineering an existing product.
  • Developing a new cable assembly or wire harness design.

Depending on the type of interconnect and design criteria used, Winchester Electronics will apply electrical modeling (simulation tools, 3-D field analysis and cascading analysis) and mechanical modeling tools (3-D mechanical analysis and thermal stress modeling) to ensure that the cable assembly products are best-in-class.

Cable assemblies often require the use of composite cables (a mix of different cable types within a single sheath) and Winchester Electronics has a qualified selection of specialist partner companies who will produce custom composite cables for each application’s unique design.

Cable Assembly Locations


AS 9100Aerospace Quality Management System
ISO 13485:2003Medical Device Quality Management System
IPC/WHMA-A-620 (Class 3)Requirements and Acceptance Standards for Cable and Wire Harness Assemblies
ISO 9001:2008Quality Management Systems
OHSAS 18001:2007Occupational Health and Safety
ISO 14001:2004Environmental Management System

The cable assemblies and cable wire harnesses are built to IPC-A-620 Class 3 standards (Requirements and Acceptance for Cable/Wire Harness Assemblies). This international standard is the industry quality standard for cable assemblies.

Winchester Electronics is a customer-focused / market-centric business and has developed the engineering expertise and the compliance requirements to support the cable assembly needs of a wide range of markets including Broadcast, Computing, Energy, Industrial, Medical, Mil/Aero, Rail/Mass Transit, Semiconductor, and Telecom/Wireless.

To meet the specific requirements of the USA Military market, the Middlebury and Franklin operations are ITAR (International Traffic In Arms Regulations) registered.

Quality Leader

Winchester Electronics is a leader and an active participant in the development of these quality standards worldwide.

IPCStandards Committee Member
ULCSARegistered Manufacturer
Wiring Harness Manufacturers AssociationMember

Learn more about Winchester Electronics Cable Assemblies

Contact us to find out how Winchester Electronics can assist you on your next custom cable assembly project.

RF Cable Assembly - Winchester Electronics

RF & Microwave Cable Assemblies

  • Broadband performance from DC to 26.5 GHz
  • Survivability in harsh environments
  • ITAR compliance
  • Phase Matching / Phase Tracking
  • Delay Lines
  • 50 Ohm and 75 Ohm Impedance

Markets include: Medical, Military/Aerospace, and Test & Measurement

Heavy Gauge Power Cable Assemblies

  • Process and Crimp Single Conductor to 750 mcm
  • Multi-conductor to 35 Kv/250 mcm
  • Volume Cable and Connector buying power
  • High flexibility Litz processing and termination
  • Overmold capability
  • Survivability in harsh environments

Markets include: Data Storage, Energy & Power Management, and Test & Measurement

Power Cable Assembly - Winchester Electronics
Complex Wire Harness - Winchester Electronics

Complex Wire Harnessing

  • Custom Configurations
  • Integration of multiple wire and cable types
  • Application of multiple interconnects
  • 100% Fit, Form, and Function validation
  • Testing to 2064 nodes
  • Reverse Engineering

Markets include: Military/Aerospace, and Test & Measurement

Custom Overmold

  • Reduced cost by eliminating mechanical back shells
  • Improved cable retention by integrating a strain relief
  • Splash proof or even waterproof
  • Reduced size over standard back shells while maintaining EMI protection
  • Color match to equipment, to the cable, or contrast from one another
  • Custom shapes, cable exits, and logos

Markets include: Medical, Military/Aerospace, Data Storage, and Test & Measurement

Custom Overmold - Winchester Electronics