Cable Assembly

Wire in this together

Wire Harness

Terminal Excellence

Cable assemblies are groups of wires or smaller cables enclosed in a single tube of material in various arrangements and configurations. Through rounds of wire processing, assembling, and quality testing, every cable assembly that leaves PGF is fully functional and ready for use.

Tried and true assembly methods lead to growth in new machinery and new industries. Whether used in transportation, EV power, medical devices, or more, PGF’s commitment to remaining on the edge of technology keeps us ahead of the game.

Assembly Methods


  • Utilize automation or manual tactics to prepare the wires.
  • Strip the cable insulation to expose the conductors.
  • Insert the stripped cable into the connector.
  • Use a crimping tool to compress the connector onto the cable, creating a secure connection.


  • Strip the cable insulation and expose the conductors.
  • Apply flux to the stripped area for better solder flow.
  • Heat the stripped area and apply solder, melting it onto the conductors to form a strong bond.

Cable Assembly Layers

The conductor layer consists of one or more metal wires or conductive materials that carry electrical signals or power within the cable assembly. Conductors are typically made of materials such as copper or aluminum, chosen for their high conductivity.

Connect with a PGF pro to learn more

The insulation layer surrounds the conductors and provides electrical insulation to prevent contact between the conductors or between the conductors and the outer layers. It protects against short circuits and ensures signal integrity by minimizing signal loss or interference.

Connect with a PGF pro to learn more

The shielding layer is an optional layer that provides protection against electromagnetic interference (EMI). It consists of a conductive material, such as a metallic foil or braided wire, that forms a barrier around the conductors, effectively blocking external electromagnetic signals from interfering with the internal signals.

Connect with a PGF pro to learn more

The jacket or sheath layer is the outermost layer of the cable assembly, providing mechanical protection and environmental resistance. It is typically made of materials like PVC (Polyvinyl chloride), thermoplastic elastomer (TPE), or polyethylene (PE). The jacket protects the internal layers from physical damage, moisture, chemicals, and abrasion.

Connect with a PGF pro to learn more

Cable Assembly Types

Cable Assembly Process

Our facility uses state-of-the-art equipment to process orders. We focus on the high-quality production of cable and wiring systems that perform reliably in various environments. Our finishing and assembly services include wire cutting, stripping, and terminating, as well as tin and solder services. Also, we offer specialized services such as hot stamping and labeling wires or cables, shrink tubing, and special packaging requests.

Suppose your company wants unique finishing details or customized labeling. In that case, our team can also add custom colors, lacing, stamping, and circuit IDs to your products, along with custom labeling and barcoding on the packaging. PGF Technology uses a combination of automation and manual assembly to produce high-quality, complex parts. Our new machinery allows fully automated wire processing for replicable results across larger production runs.

Cable Preparation

Strip the outer jacket of the cable using appropriate tools to expose the individual wires or conductors within. This step ensures access to the conductors for termination.

Conductor Termination

Trim and prepare the exposed conductors by stripping the insulation from the ends to achieve a clean and consistent surface. This enables proper electrical contact and connection with the connectors.

Connector Attachment

Attach the connectors to the cable ends, ensuring the proper alignment and orientation. This step may involve crimping, soldering, or other methods depending on the connector type and assembly requirements.

Shielding Termination (If applicable)

If the cable assembly includes shielding, terminate and connect the shielding to the appropriate ground points or connectors. This ensures effective shielding against electromagnetic interference (EMI) and maintains signal integrity.

Cable Assembly Testing

Perform testing and verification of the cable assembly to ensure proper continuity, electrical performance, and functionality. This may involve checking for shorts, opens, or other defects using continuity testers, multimeters, or specialized testing equipment.

Insulation and Strain Relief

Apply insulation materials, such as heat shrink tubing or insulating tape, to cover and protect the exposed conductors and connections. Additionally, incorporate strain relief mechanisms, such as clamps or molded boots, to prevent stress on the cable and connectors.

Final Inspection and Quality Control

Conduct a thorough visual inspection of the completed cable assembly to check for any physical defects, such as misalignment, loose connections, or inadequate insulation. Ensure that the cable assembly meets the required specifications and quality standards.

Labeling and Identification

Apply labels or markings to the cable assembly for identification, including information such as part numbers, serial numbers, or other relevant details. This helps with inventory management and traceability.

Industries Served

Cable assemblies find extensive use across various industries and applications. They are crucial components in sectors such as telecommunications, automotive, aerospace, medical devices, industrial equipment, and consumer electronics, providing essential connectivity and signal transmission for data, power, and control purposes. Whether it’s enabling communication networks, supporting automotive electrical systems, facilitating medical equipment connectivity, or powering industrial machinery, cable assemblies play a vital role in ensuring efficient and reliable operations across diverse industries.

robotic assembly line

Robert W. Calhoun Jr. | McNaughton McKay

The bottom line is that PGF delivers quality cables. This type of performance is the basis for a sound working relationship with PGF..

Download eBooks

Read the latest industry news from our eBooks catalog, including updates on electronic assemblies!

Read Cable Assembly Articles

Browse our blog posts to find cable assembly articles that touch on design, assembly processes, machines, and more!

Electrical components

Harness Your Power