At SAISONIC, we provide end-to-end wire harness and custom cable assembly solutions, guiding every project from concept to finished product. We understand that standard cables often cannot meet the unique needs of specific applications, so we offer flexible, precise engineering and customization to ensure every cable perfectly fits your equipment, environment, and performance requirements.
First, we should fully understand your needs:
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Application assessment
Evaluation of the operating environment, including industrial automation, medical devices, robotics, data centers, or harsh outdoor conditions.
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Performance goals
Confirmation of key parameters such as power, data, signal, high-frequency RF, bandwidth, speed, and power consumption.
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Mechanical & environmental requirements
Determine bending cycles, tensile strength, temperature range (high/ow), flame retardancy, oil/chemical resistance, and UV resistance determination.
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Regulations & certification
Provide guidance on UL/CSA, CE, RoHS, REACH, CCC, and other market-specific certifications.
Our engineering team transforms your wire harness and cable assembly requirements into manufacturable technical solutions:
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Connector selection & customization
Choosing the right brand and model based on interfaces such as USB, HDMI, M8/M12, D-Sub, or RJ45, or design non-standard connectors.
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Cable design & material selection
Selecting conductors (OFC, tinned copper, copper-clad aluminum), insulation, and jacket materials (PVC, PUR, TPE, silicone) for flexibility, durability, and environmental compatibility.
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Shielding & EMI/RFI protection
Designing foil, braided, or hybrid shields to ensure signal integrity.
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Core structure & color coding
Customizing core counts, twist pitch, and color coding for easy installation and maintenance.
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Prototyping & sample production
Building samples for testing and validation.
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Documentation
Providing detailed specs, wiring diagrams, layout drawings, and 3D models (STEP files).
With advanced production equipment and a rigorous quality management system, we transform your designs and specifications into high-quality finished products.
- Precision cable processing: Accurate cutting, stripping, and inner insulation removal.
- Crimping & soldering: Fully or semi-automated crimping and soldering to ensure strong, reliable terminations and excellent conductivity.
- Overmolding & Injection: Secondary molding for connectors to improve strain relief and sealing performance.
- Assembly & Integration: Precision assembly of connectors and cables, including braiding, heat shrink tubing, labeling, and other accessories as required.
- Quality Control: 100% electrical testing, including continuity, dielectric, insulation resistance, and HIPOT tests throughout the production process.
We conduct a comprehensive range of tests to ensure every cable assembly and wire harness meets customer specifications and industry standards.
- Electrical Performance Testing: Measurement of impedance, capacitance, delay, crosstalk, etc.
- Signal Integrity Testing: High-frequency performance testing using network analyzers.
- Mechanical Performance Testing: Bend testing, tensile testing, mating cycles.
- Environmental Reliability Testing: Thermal cycling, salt spray, vibration tests.
- Certification Test Support: Assistance with third-party certification testing.
We offer a range of value-added services to provide greater convenience and support for our customers.
- Harness Assembly: Combining multiple cables into complex assemblies with bundling, sleeving, and labeling options.
- Labeling & Identification: Permanent labels, laser marking for clear identification and maintenance.
- Custom Packaging: Blister trays, reels, anti-static packaging, or other special packaging as required.
- Cable Management Accessories: Cable ties, clips, mounts, protective sleeves.
- Technical Support: Ongoing consultation and troubleshooting.
- Flexible Orders: From prototypes to large-scale production.
- Quality Assurance: Defined warranty and support policies.
- Continuous Improvement: Optimize design and reduce costs based on feedback and production data.
Delivering reliable wire harnesses and cable assemblies tailored to your specific wiring needs!
