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At Captor Corporation, we specialize in cable assembly fabrication and we manufacture a wide range of cable assemblies for a variety of customers. Our extensive experience in manufacturing and testing techniques ensures that our customer’s expectations are always satisfied. We design for the military, electromechanical, aerospace, and automotive industries and can create designs of various sizes and types of wire, crimp and solder terminals, and connectors. There isn’t an assembly we can’t design and manufacture.

Using solid, stranded, or other types of wire in 40 to 4/0 AWG, assemblies can be terminated with military, commercial, D-Sub, IEC, crimped, or other specialized connectors. A test plan is created for all assemblies and a test report issued when testing is complete. In addition, our on-staff IPC/WHMA-A-620 Certified Trainer ensures our cable assembly builders are up to date on certifications and best practices.

Captor Corp’s cable assembly capabilities are wide-ranging. For additional information on how we can provide you with a ‘just right’ solution, please contact Captor Corp today.

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At Captor Corporation, we have extensive experience designing and manufacturing cable assemblies for industrial customers, including those in the aerospace and military industries. For these customers, we offer high-quality build-to-print solutions that meet the needs of their applications, regardless of the altitude, temperature, electrical, shielding, and other requirements.

Our aerospace and military cable assemblies can be engineered to fulfill MIL-STD requirements for extreme environmental situations and integrated with military-grade connectors, including the following military specifications:

  • MIL-DTL-5015
  • MIL-DTL-24308
  • MIL-DTL-26482
  • MIL-DTL-38999
  • MIL-DTL-83513
  • MIL-DTL-83723
  • MIL-PRF-39012
  • MIL-PRF-55339

After the manufacturing stage, they are subjected to rigorous testing to verify they comply with customer and industry standards. As necessary, our testing processes include:

  • Altitude testing
  • Temperature cycling testing
  • Shock testing
  • Vibration testing
  • Electrical testing
  • Mechanical testing
  • Environmental exposure testing

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Many industry professionals use the terms “wire harness” and “cable assembly” interchangeably. While the two have similar functions, they are distinct products with different purposes. Understanding the differences between them is the key to choosing the right one for your application.

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A wire harness consists of wire or cable or a bundle of wires and cables sheathed in a protective covering made from inexpensive and lightweight material. This exterior cover is primarily used to organize the wires and cables. While it also provides low-level protection to the internal components, most of the protective measures come from the individual coverings surrounding each wire or cable. These components are typically used in indoor environments where they are less likely to be exposed to harsh conditions such as extreme temperatures or pressures.

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A cable assembly refers to a collection of wires or cables enclosed within a durable exterior sheath. Compared to a wire harness, its covering is made from more heavy-duty materials—e.g., shrink-wrapped thermoplastic or vinyl—for greater durability and reliability in extreme conditions. These qualities make it more appropriate for use in equipment exposed to harsh environments.

Cable assemblies are generally designed and built to meet the unique specifications of the application, including in regard to the size needed and the conditions encountered. For example, they are available in various sizes and shapes with options for cable and wire shielding against abrasion, compression, friction, heat, and more. This broad customizability allows them to be used in highly specialized applications with exacting performance and regulatory standards, such as those found in aerospace and military industries.

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Equipped with over four decades of industry experience, the team at Captor Corporation has the knowledge and skills needed to design and engineer a cable assembly or wire harness solution for virtually any aerospace or military industry application. Regardless of the exact requirements, we will work with customers to ensure the assembly we provide fully meets their standards.

To learn more about our cable assembly and wire harness capabilities or partner with us on your next project, contact us or request a quote today.

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General Capabilities

Custom Spec
Custom Engineering Design
Build to Print

Process

Design
Engineering
Layout
Manufacturing
Assembly

Testing
Verification
Consulting
Prototyping
Research and Development

Equipment

Automated
Manual

Cables / Harnesses

Electromechanical
Aerospace

Automotive
Passive Component-to-Wire

Components

Shrink Tubing
Wires
Connectors
Molding
Terminals

Wire Ties
Shielding
Strain Reliefs
Clamps
Clips

End

Lug
Cut
Stripped and Tinned

Connectors

Military
Commercial

Wire Gage Range

40 to 4/0 AWG

Inspection

100% Test
Visual
AQL

Testing

Altitude
Temperature Cycling
Shock
Vibration

Electrical
Mechanical
Environmental

Quality Control

Test Plan
Test Report

Secondary Operations (In-House)

Assembly
Machining
Forming

Bending
Welding
Quick Turn Prototypes

Production Volume

Prototype to Large Scale Production Runs

Typical Lead Times

1 week (Stock)
10 to 12 weeks (Custom)
1 to 3 weeks (Prototype)

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Industry Focus

Electrical
Electronic
Military

Aerospace
Commercial

Industry Standards

AS9100 Rev C
ISO 9001:2008

AS9100 Rev C
ISO 9001:2008

File Formats

SolidWorks
AutoCAD
PCAD (Circuit Boards)