The following sections highlight the core advantages that distinguish VSE:
Frayed or damaged cables are a common frustration, from cracked insulation on old plugs to bent phone chargers that no longer work. Beyond inconvenience, they can create safety hazards and disrupt signal continuity. In high-performance systems, the stakes are even higher.
That’s why VSE’s engineering team designs and manufactures printed circuit board (PCBA) cable assemblies to extend service life. These assemblies are especially critical for high-power lines and components sensitive to electromagnetic interference (EMI), which is unwanted electrical noise that disrupts signals. By addressing these risks early in the design and manufacturing process, VSE helps ensure your systems perform reliably where it matters most.
| Description | Pros | Cons | \Automated Assembly Ready? | |
|---|---|---|---|---|
Cable Ties |
A cinching tool pulled taut and locked in position |
|
|
YES |
Tape |
Adhesive wrap-around wires that can be insulative |
|
|
YES |
Woven Braid |
Woven material around wires |
|
|
YES |
Heat-shrink Tubing |
A sheath around wires; heated to mold to shape |
|
|
NO |
Spiral Wrap |
A system for cable-of-cables |
|
|
YES |
Insulative Sleeving |
A loose-fitting bundling option |
|
|
NO |
Slit-wall Loom Tubing |
A rugged sheath for physically demanding operations |
|
|
YES |
A signal is only as strong as its reliability. At the board level, minimizing loss, reducing noise, and limiting EMI are essential for performance. These same priorities carry into inter-board connections, but the added physical layer of cabling requires further considerations.
The following best practices help preserve signal quality and improve manufacturability:
Key elements of this process include:
Cabling plays a critical role in transmitting both power and data within electronic systems. A cable is a group of wires enclosed in a common sheath, while a wire harness organizes inter-board connections. Beyond organization, cables protect the conductors and shield the surrounding environment inside the enclosure. When designed and manufactured correctly, cabling also improves electrical performance in several key ways:
Cables reduce EMI by limiting the exchange of signals between enclosed wires and their environment. For lower levels of EMI, a simple twisted pair is often an effective solution.
Challenges arise with high-speed signals, which may still generate interference, or when multiple twisted pairs couple together due to similar twist rates. In these cases, shield-jacketed cables or shielding tape beneath the sheath provide stronger protection than twisted pairs alone.
Over time, wires that brush or rest against surfaces can wear through their insulation and expose the conductor. Cable sheaths protect against this by adding an extra barrier that prevents damage from reaching the wire itself and by increasing abrasion resistance. In some applications, sheaths also protect against crushing forces, further extending service life.
Loose wires inside a system can snag, tangle, or pull against connectors, leading to damage or premature failure. A cable assembly eliminates this risk by keeping wires organized within a single, protective bundle. This cohesion reduces mechanical stress on individual conductors, helps maintain stable electrical connections, and supports cleaner, more reliable system performance over time.
A well-designed cable assembly is both durable and flexible. By maintaining proper bend radii, the assembly reduces mechanical stress on conductors, minimizing wire fatigue and extending service life. Without this control, cables in high-density systems can kink or break down over time, leading to unreliable connections and costly maintenance.
High-quality cable assemblies are critical for maintaining performance and reliability across inter-board connections. Even the strongest designs can be limited without the right infrastructure in place. That’s why VSE builds custom assemblies tailored to the specific needs of your single- or multi-board box build. Our turnkey solutions for PCBAs are designed to optimize features and functionality at every stage of the production process.
VSE delivers assemblies with the precision, care, and attention to detail that complex projects demand. When reliability matters most, partnering with VSE means working with a U.S.-based manufacturer dedicated to building each assembly to the highest standards.
Still searching for the right cable assembly partner? Let our experts handle your requirements today.