Custom Cable Assemblies

Our innovative Cable Design Tool is at the very foundation of every cable assembly built at Pickering. This intuitive and visual tool lets you create, save, and organize your projects seamlessly. It has all the features needed for designing fully functional cable assemblies, including a vast library of connectors, wires, and backshells, the ability to collaborate on a design or chat with our cable technicians. Best of all, it´s free and runs in your browser with no installation needed.

Wire processing is a critical step in cable assembly, involving cutting, stripping, crimping, and terminating wires to precise specifications. At our facility, we offer comprehensive services that include:

Automated single wires processing and termination

• Wires cutting
• Stripping
• Crimping
• Double crimping
• CFA (crimp force analyzer) control

Semiautomatic multiconductor processing machine

• Stripping with automatic cut detection
• Multi sequential stripping
• One process strip and crimp with CFA

Coaxial Cable Stripping
Wire termination capabilities

• Soldering
• Crimping
• Wire wrapping

Marking technology

• Heat-shrinkable label printing

We offer the option to customize single or multi-core cables and their various features to meet your specific requirements.

Custom single-core conductors:

• Custom Insulation Material: Choose from PTFE, PFA, PVC, and more, available in single or double color.
• Custom Stranding: Customize the number of strands of the core, including options for strand plating or prebonding.

Custom multi-core cables: 

• Custom Twisting: Specify the number of twists per meter to match your desired electromagnetic performance.
• Cable Shielding: Choose between foil, braided shielding, or a combination of both.

Additionally, we offer whole reel twisting.

All cables undergo thorough testing, including 4-wire, up to 2KV HiPot, and various other tests tailored to client specifications.

Our advanced testing equipment allows us to run a wide range of both low and high-voltage tests. This includes high voltage dielectric withstand (DW) and insulation resistance (IR) testing, as well as detecting error locations for opens and shorts. In addition, we can test built-in components to ensure the cable’s overall performance.

What we test on our cables:

• Standard test:
  LV testing (4V, 1mA to 1A)
  • Continuity testing (shorts, missing wires, missing contacts)
  • 4-Wire path resistance (0.001 Ω to 10 Ω ± 2% ± 0.001 Ω)
  • Component test (Diodes, Resistors, Capacitors)
  HV testing (100 to 2000VDC)
  • Insulation Resistance (5 MΩ to 1000 MΩ ± 10%)
  • Dielectric Withstand Test (Leakage, Overcurrent)
• On-demand – may include extra set up charge:
  • Twisted Pairs (verify proper pairing in twisted pair cables)
  • Values of all insulation resistances
  • RF testing (insertion loss, VSWR)
  • PDF test report
• The test report includes:
  • All tester settings according to max specs of the cable assembly
  • Max path resistance on the cable
  • 4-Wire resistance of each path
  • Any custom values according to customer demands

With our CNC capabilities, we can offer fully customized aluminum backshells tailored to your specific requirements. Our capabilities allow for rapid prototype development, ensuring high-quality and durable solutions.

Aluminum Anodized Backshells

• CNC and Laser Engraving Capabilities: Custom logos for brand enhancement.
• Stainless Steel Custom Screw-Locks and Clamps: Ideal for large quantities and durability.
• Color Anodizing

Diecast Backshells

• Nickel-plated sandblasted Zinc Alloy: Available starting from 500 pieces.

Overmolding Capabilities: Provides a cost-effective alternative to traditional backshells.

Potting: Enhances durability by filling the complete electronic assembly with a solid or gelatinous compound.

Front Panel & Box-Builds

Thanks to our own PCB department, we can seamlessly integrate PCB and cable components. For instance, we can transform connectors designed for circuit boards or panels into fully functional cable connectors. We offer comprehensive services that include:

In-house Design

• LVDS and Controlled Impedance: Advanced PCB designs tailored to your specific requirements.

Manufacturing Capabilities

• Free Via-in-Pad: Via-in-pad technology offers PCB designers increased design freedom, improved efficiency with significantly faster routing, and enhanced reliability. This service is available at no additional cost, starting from a single unit.

PCB Assemblies

• Robotic Soldering: Ensures precision and consistent quality for each solder joint, making it an economical choice.
• Wave Soldering for THT Components: Reliable and efficient soldering for through-hole technology components.
• SMT Machine:  Offering high-speed and accurate surface-mount technology assembly, precise component placement, and exceptional reliability.
• Vapor Phase Soldering:  Ideal for low to mid-volume production, offering superior thermal management, high-quality solder joints, and reduced defects.
• AOI (Automated Optical Inspection): Ensures the highest quality through precise optical inspection of PCBs.