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Custom Cable Manufacturing

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Custom Cable Manufacturing<br><br>Premier US Manufacturer of Custom Cable Assemblies, Wire Harnesses and Box Builds.Interconnect and assembly solutions for OEM applications that guarantee unmatched quality, reliability, and speed.<br>For more about us visit https://www.circuitassembly.com

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Custom Cable Manufacturing

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  1. Custom connectors, cable assemblies, box builds, and pcba's Integrated SOLUTIONS c i r c u i t a s s e m b l y . c o m

  2. PARTNERS FOR SUCCESS Our Mission At Circuit Assembly Corp, we believe that success is built on a foundation of strong relationships; with our employees, our customers, and our community. Our vision is to create an exceptional workplace where hardworking and driven individuals thrive, ensuring a balanced life for them and their families. By fostering a culture of excellence, innovation, and respect, we empower our employees to grow and succeed while delivering superior products and services. Our commitment to outstanding customer service drives us to go beyond expectations, addressing the challenges facing our customers with tailored solutions that create lasting value. Together, we build more than electronics, we build trust, opportunity, and a future where everyone benefits. DELIVERING RELIABLE QUALITY FOR 55+ years

  3. INDUSTRIES SERVED Circuit Assembly Corp is a world-class contract manufacturer specializing in medium to high volume electro-mechanical assemblies. We serve a diverse range of industries including aerospace, medical, industrial, and commercial OEMs. Our comprehensive services encompass custom cable assemblies, box builds, and printed circuit board assemblies (PCBA). By having multiple manufacturing locations, we tailor our solutions based on customers volume and lead time requirements. ▪ Aerospace ▪ Datacom ▪ Electronics ▪ Energy ▪ Industrial ▪ Infrastructure ▪ Medical ▪ Transportation

  4. OUR PROCESS End End- -to to- -end manufacturing expertise from your initial idea to final assembly. end manufacturing expertise from your initial idea to final assembly.

  5. OUR CAPABILITIES Custom Connectors At Circuit Assembly, we pride ourselves on our ability to produce custom connectors to meet our customers specific requirements. We specialize in 'made-to-spec' and full custom connectors at mid and high volumes. This includes basic modifications to an existing product to fully customized solutions based on our customer's needs. Our experienced Engineering team is capable of creating models and drawings for competitor's parts, and producing custom solutions, eliminating the concerns of end-of-life products. Our Engineering and Production teams capabilities allow us to move quickly from concept to production in just 12 weeks, with prototypes in as little as 4 weeks after drawing approval. Quick turn samples available based on 3D printing rapid prototyping.

  6. OUR CAPABILITIES Custom Cable Assemblies At Circuit Assembly, our custom cable assemblies are engineered to solve the unique challenges of each application, whether it’s electrical performance, environmental protection, signal integrity, or mechanical stress relief. Our Capabilities Span: ▪ Overmolded Cable Assemblies in special sizes or shapes to fit with customers application. Angled molds for special routing. Chassis mounted strain reliefs. Custom mold for application fitment. ▪ High-speed data and hybrid signal/power cables for performance, compact layouts, and reduced cable count. ▪ Custom breakouts, lengths, and connector configurationsto match your system’s mechanical and electrical requirements. ▪ Shielded cables for signal integrity in high-interference environments.

  7. OUR CAPABILITIES Wire Harnesses Our wire harnesses are custom-built to organize and protect electrical systems, streamlining installation, improving durability, and reducing risk of failure. We offer: ▪ Custom routing and bundling to simplify integration into tight or complex enclosures. ▪ Connector-to-connector harnesses with exact lengths, labels, and terminal types. ▪ Protective sleeving and jacketing for abrasion resistance, heat shielding, and flexibility. ▪ Pre-tested harnesses with continuity and functionality checks before shipment.

  8. OUR CAPABILITIES PCBA (Printed Circuit Board Assembly) Circuit Assembly provides full-service PCBA offerings, from sourcing and assembly to inspection and testing. Our facilities handle both surface mount (SMT) and through-hole technologies, supporting everything from quick-turn prototypes to full-scale production runs. We Specialize In: ▪ Component Sourcing & Procurement: Leveraging a global supply chain to secure reliable, cost-effective components. ▪ Mid to High Volume Capability: Multiple global locations to satisfy all time and volume requirements. Our smaller volume and quick-turn projects are handled in California, while our higher volume projects are cost effectively manufactured in China. ▪ Inspection & Testing: Comprehensive quality control, including AOI (automated optical inspection), functional testing, and X-ray for components. ▪ Conformal Coating & Encapsulation: For added protection in harsh environments.

  9. OUR CAPABILITIES Box Builds Circuit Assembly offers comprehensive box build assembly services, providing end-to-end solutions for integrating electronic and mechanical components into complete systems. Our Capabilities Include: Enclosure Integration: Assembly of custom enclosures housing PCBAs, wiring, and other components. ▪ Cable and Harness Installation: Precise routing and installation of cables and wire harnesses. ▪ Mechanical Assembly: Integration of mechanical parts, including switches, displays, and connectors. ▪ Programming: Our technical team can support programming of firmware/software on your build as ▪ needed as part of the assembly process. Testing and Quality Assurance: Rigorous functional testing to ensure product reliability and ▪ performance based on customers individual requirements. Testing equipment can be custom built for your build or consigned to our team during the manufacturing process. Packaging and Labeling: Final product packaging, labeling, and documentation ready for distribution. ▪

  10. OUR CAPABILITIES Prototype & EOL (End-Of-Life) At Circuit Assembly, we support your product’s full lifecycle from early-stage prototypes to navigating EOL transitions. Our Capabilities Include: Prototyping: We offer rapid-turn cable assembly prototypes for early validation, testing, and ▪ design refinement. Our agile process reduces development time and accelerates time-to-market. Prototype Volume Builds: Perfect for pilot runs and niche products, with full support on DFM ▪ (Design for Manufacturability). EOL Solutions: When components are discontinued, we support sourcing alternatives, re- ▪ engineering assemblies, and maintaining production continuity to minimize delays, costs, and compliance risks. Alternatively, we are also capable of reverse engineering and tooling EOL components to elongate the life cycle or your product line instead of having to redesign the entire product due to a component that has gone EOL.

  11. OUR SOLUTIONS Turnkey & Consignment From fully managed turnkey builds to consignment and hybrid models, Circuit Assembly adapts to your workflow. Whether we source all components or work with customer-supplied kits, our flexible approach ensures consistent quality, faster turnarounds, and streamlined cable assembly production tailored to your needs.

  12. TRUSTED BY BRANDS YOU KNOW FROM CUTTING-EDGE STORAGE AND MEDICAL TO NEXT-GEN SOLAR, WE ARE COMMITTED TO EXCELLENCE.

  13. QUALITY ASSURANCE Quality assurance is the foundation upon which our company’s reputation and success stand. Our comprehensive processes include: ▪ Rigorous Quality Assurance: ▪ We strive to created Enhanced Confidence in Quality and Reliability. ▪ We have implemented robust quality management systems, ensuring consistent quality and reliability of products. ▪ Customer Satisfaction: ▪ We are Customer-Focused. This standard encourages companies to prioritize understanding and meeting customer needs, leading to higher satisfaction. ▪ Supply Chain Reliability: ▪ Traceability and Control of our suppliers and Reduced Risk of Counterfeit Parts. ▪ We seek to ensure that customers receive genuine products. ▪ All our suppliers are vetted prior to inclusion on the Approved Supplier List.

  14. QUALITY ASSURANCE Circuit Assembly Corp QMS is Certified to the ISO 9001:2015 and AS9100D Standard. ISO 9001:2015 & AS9100D: Built for Trust, Driven by Quality: ▪ Global Recognition: ▪ AS9100D is a globally recognized standard within the aerospace industry, demonstrating a supplier's commitment to quality. ▪ Risk Management: ▪ AS9100D emphasizes risk management, helping to prevent defects and ensuring the safety and reliability of products. ▪ Focus on Customer Feedback: ▪ AS9100D emphasizes seeking and analyzing customer feedback to improve processes and products through customer satisfaction surveys and customer scorecards.

  15. TESTIMONIALS What our clients haVE to say “…you have worked diligently behind the scenes to help ensure that BD can continue to provide much-needed medical equipment and technologies to the healthcare heroes. “ "I have a lot to thank you and Circuit Assembly for your work and support. Roger Caetano - Director, Engineering, Hycor " We have had nothing but positive feedback from our customers regarding solar connectors from Circuit Assembly. “ " Circuit Assembly's quality of work is reliable and top-rated.” Ronald E. Brown - Buyer, Astronics Buddy Martell - Inside Solar Sales, CED Greentech Tom Polen - CEO and President, BD

  16. CASE STUDY project showcase The Challenge Balancing cost-efficiency with quality and demand—the company needed to minimize overhead without compromising product integrity or falling behind rising sales volume. Our Solution ▪ Streamlined production with ready-to-run assembly lines and expert manufacturing support BOX BUILD ▪ Ensured top-tier quality through established QA processes ▪ Freed up internal resources so Ronin could focus on design, marketing, and innovation

  17. CASE STUDY project showcase The Challenge A leading medical technology company faced a critical disruption when their manufacturer discontinued essential components for a specialized cable assembly used in remote hospital suites— threatening system reliability and continuity of care. Our Solution ▪ Delivered $60K in cost savings by eliminating the need for retooling Eol solution ▪ Engineered custom-fit components to ensure seamless integration and optimal performance ▪ Established a long-term partnership with a strong commitment to ongoing support and innovation

  18. DEVELOPMENT ROADMAP 2025 AND Beyond Opening Third assembly location in Vietnam ▪ ITAR compliance in process with target in August 2025 ▪ DDTC Registered ▪

  19. CHINA FACILITIES INFORMATION INTERNATIONAL PRODUCTION FACILITY (WHOLLY OWNED) High Volume Cable Assemblies - Mid-High Volume support, Overmolding, Custom Design and Development, Connectors 44,574 sq. ft – Production Space Shenzhen, China sales@circuitassembly.com www.circuitassembly.com Tel: 949.855.7887

  20. USA FACILITIES INFORMATION CIRCUIT ASSEMBLY HEADQUARTERS & U.S. PRODUCTION Fast-Turn Cable Assemblies & Box Build Assembly 21,592 sq. ft – Office/Production Space 6 Autry Irvine, CA 92618 sales@circuitassembly.com www.circuitassembly.com Tel: 949.855.7887

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