Precision Cable Assembly Services Tailored to Your Needs

VSE Provides Precision Cable Assemblies Engineered For Reliability And Performance.

Cable assembly services bundle and sheathe wires.

Why Leading Industries Choose VSE

Companies in the medical device, aerospace, defense, and industrial technology sectors choose VSE because quality, compliance, and reliability are built into every process we execute and every product we manufacture. From cable assemblies to full PCB production, we combine engineering expertise with rigorously controlled, U.S.-based operations to meet demanding technical requirements and strict timelines. Every project is supported with transparency, quality, and a focus on long-term success.

The following sections highlight the core advantages that distinguish VSE:

Decades of Proven Experience

With over 40 years of experience in electronics manufacturing, VSE has refined our processes to minimize risk and improve outcomes. Our teams have encountered and solved a wide range of technical challenges, giving us the insight to anticipate issues before they affect your build. This experience translates into consistent quality, reliable assemblies, and smoother project execution from prototype through production.

ISO-Certified Quality Standards & Lean Domestic Manufacturing

VSE’s ISO 9001 and ISO 13485 certifications confirm compliance with the most rigorous quality standards in the industry. Every build follows documented processes, detailed traceability, and systematic testing to safeguard performance and consistency. With our U.S.-based operations, we also provide the supply chain security, responsiveness, and oversight that global manufacturers increasingly demand.

Rapid Turnaround Without Compromising Quality

Speed to market is critical, but never at the expense of reliability. VSE streamlines the transition from prototype to production with agile processes and live engineering support, reducing costly delays and design revisions. Our teams move quickly while maintaining strict quality controls that protect your product’s long-term success.

Built for Performance Where Reliability Matters Most

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 (PCB) 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.

Trusted Cable Assembly Methods, Handled by VSE Experts

Different applications demand different cabling solutions. Each method offers unique strengths and limitations, from flexibility and protection to cost and scalability. The table below outlines common cabling options, with their advantages, drawbacks, and suitability for automated assembly.

Common Cabling Options
	Description	Pros	Cons	Automated Assembly Ready?
Cable Ties	A cinching tool pulled taut and locked in position	Inexpensive Quick manual installation Highly applicable	Unsuitable for cabling in tight spaces/opening	YES
Tape	Adhesive wrap-around wires that can be insulative	Handles wires of irregular shapes Inexpensive Marginal resistance to chemicals and moisture	Relatively low thermal resistance	YES
Woven Braid	Woven material around wires	Protection against abrasions and chemicals The unique structure allows moisture and heat to drain from the cable	Expensive	YES
Heat-shrink Tubing	A sheath around wires; heated to mold to shape	Minimal sheath width and space. Provides strain relief	Reduces cable flex	NO
Spiral Wrap	A system for cable-of-cables	Most durable to surface abrasion Supports intricate cable breakout for greater organization	Reduced flexibility High-cost	YES
Insulative Sleeving	A loose-fitting bundling option	Adds protection while maintaining flexibility Additional dielectric layer for improved electrical resistance	Performs best in simple cable assemblies	NO
Slit-wall Loom Tubing	A rugged sheath for physically demanding operations	Best protection against a range of physical modes (abrasion, impact, crushing)	Expensive Loss of flexibility	YES

Maintaining High-Quality Signals Across Connections

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:

Enlarge Bend Radii As Much As Possible

The bend radius is the minimum curve a cable can withstand without damage. Larger bend radii reduce stress on connectors, extend service life, and improve manufacturing throughput.

Tight Tolerances Only When Necessary

Tolerancing is critical at the board level. In box-builds, however, overly strict requirements restrict flexibility, reduce yields, and significantly raise per-unit manufacturing costs.

Reference Length Dimensions From The Back Of Connectors

Measuring from the connector back provides more accurate slack, prevents strain, and avoids extra material costs that can quickly become prohibitive at scale.

FROM DESIGN TO CUSTOM-BUILT CABLE ASSEMBLIES

Cables must perform reliably to handle the demands of multiple system interconnects. At VSE, our engineers work from project data to create a tailored build and test plan for every assembly.

Key elements of this process include:

Assembly drawing

A detailed diagram of the cable assembly with build instructions, connector callouts, and label positions. It guides designers and technicians through accurate component placement and attachment.

Wire list

A reference document showing connector pin-outs, wire colors, net information, and images of connector layouts. It helps simplify assembly while ensuring proper connections.

Test specifications

Defined procedures for in-process and final inspections. These checks verify quality, confirm performance, and support long-term reliability before assemblies leave production.

Cabling Built for Signal Integrity, Strength, and System Life

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:

Electromagnetic shielding

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.

Mechanical protection

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.

Cohesiveness

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.

Flexibility And Bend Radius Control

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.

Custom Cable Assemblies Backed by 40+ Years of Expertise

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 PCBs 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.