NiobiCONN™ connectors can be connected and disconnected underwater, at any depth, with no corrosion or safety hazards.
iCONN Systems is equipped with the ability to solve all of your custom connector design and interconnect needs. Some applications require a full cable assembly and connector design, where we take our customers through our custom engineered process and develop a product from the ground up. Some applications, meanwhile, are less stringent and need a standard, off-the-shelf connector. iCONN Systems excels in both, making us the ideal custom cable manufacturer.
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Customer needed a connector to withstand 500 lbs of straight pull force, while incorporating a 30 awg coax wire
iCONN designed and developed a solution that included:
Customer needed a product to survive in burning buildings - people's lives at stake.
iCONN developed a repeatable process to build robust assemblies with zero defects in application.
In application, the Customer's solution was not aesthetically pleasing or robust.
iCONN developed a robust assembly method using a custom overmold on titanium housings. Marketing had a visually appealing product for an easier sell.
Customer was experiencing field-failures due to a previous custom design. The current supplier did not factor in the application environment.
iCONN designed and printed prototypes for field testing to win the business and prove that our design would survive.
The customer needed a low profile battery housing that would allow the end-user to replace batteries, remain sealed and meet industry regulations.
iCONN designed and developed a battery housing to fit within the given real estate, and used a custom overmolding process to ensure everything is water-tight.
The customer needed a sensitive PCB sealed in a cable assembly - and needed it in 3 weeks!
iCONN's low pressure overmolding capability and quick-turn tooling program delivered product to the customer cost-effectively and on-time.
Customer needed a PC Board mounted connector that would also seal when installed into their product housing.
iCONN designed a connector that could be wave soldered to a PC board and create a watertight seal when installed into the housing.
Customer needed a low-profile connector capable of handling 16 positions and a standard off-the-shelf item was not available.
iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.
Customer wanted a connectorized end cap for a light bar that meshed with the size and geometry of their light bars.
iCONN designed an end cap overmold with an integrated connector. This end cap sealed the entire light bar from outdoor elements.
Customer needed a cheap, high-volume connector to carry power from unit to unit in series.
iCONN designed cheap, yet robust contacts for this connector, and automated assembly equipment to meet high volume demand.
Customer needed a connector that mounted to a PC board and would have many sensor replacements.
iCONN designed a quick-connect / disconnect solution that would simplify sensor changes for the end-user.
Customer needed a low-profile connector capable of handling 16 positions and nothing off-the-shelf would work.
iCONN designed and tooled a connector to minimize overall height of product while maintaining an IP67 rating.
iCONN is a leader in new product development. With a team of skilled engineers and custom cable manufacturers, our custom connector design strategies can be tailored to your needs. In custom cable manufacturing, we’re able to walk you through the process and go over the details ahead of implementation to help you avoid a costly mistake. We carefully consider the guidelines of the applications to make sure they meet the required specifications.
iCONN’s custom cable connectors are developed in-house. As custom cable manufacturers, we understand that not all applications are the same, and off-the-shelf connectors can limit design intent and product functionality. That’s why our cable assembly manufacturing operatives work directly with your team to develop and manufacture specifically engineered solutions.
At iCONN, our engineers develop, prototype, and manufacture custom-engineered connectors and overmolded cable assemblies. We have a variety of turnkey solutions available, but our abilities in customization are where we truly shine. Our team has over 200 years of combined engineering experience and over 120 years of experience in the connector marketplace. With this expertise in the cable assembly manufacturing sector, we are able to tackle almost any new challenges our customers present to us.
We see our customers as our partners and we strive to provide them with quality components that perform reliably in their applications. This helps our customers to stay successful in the marketplace and reduces the worry of connector or cable assembly failure.
Through our process, we account for application constraints, durability ergonomics, and audio and technical features and create a turkey or custom cable solution to ensure your product will meet the demands of your application.
If you’re interested in having us as your custom cable manufacturing partner, we can meet with you to make sure we fully understand your application and then make recommendations that will fit your needs. We are dedicated to serving a wide variety of industries and are able to assist with many different projects.
Design details that are specific to how cables and connectors are adjoined include:
This refers to the literal shape of the connector head, which can be customized to fit into tight spaces or unique device designs. Options include:
This is how a connector and cable assembly are affixed to a device (such as a computer or appliance). Options include:
This refers to how one connector end mechanically joins with another connector end. Options include:
This is the method used to adjoin a wire to a wire or a wire to a terminal. Options include:
This refers to the diameter of the wire, which determines the amount of electricity the wire can carry safely and the amount of resistance present in an electric circuit. Options include:
This refers to the pins and sockets found on each connector end that fit together to complete an electrical connection. Options include:
These are typically a type of metal that determines the conductivity of the cable and connector and, thus, the strength of the electrical current. Options include:
These are materials used to prevent an electrical current from coming into contact with other wires, equipment, or users. Options include:
These are materials used in an injection molding process to permanently combine a cable and connector into one single, seamless part. Options include:
Get the guide: Everything You Need to Know About Overmolded Cables.
This refers to details that enhance the appearance, installation, and user experience of a connector and cable assembly. They include:
These are design elements that physically enhance how a connector and cable assembly performs in a specific environment or application. They include:
While each application requires a different solution, our processes for creating custom cable manufacturing remain the same. We start with design, verification, prototyping, and validation testing prior to the manufacturing process. Once we get approval, we begin cable assembly manufacturing so that you can achieve the unique solution you’ve been looking for.
Discover the general process of creating custom cable connectors below:
Just like that, the custom cable assembly process is complete, and you will have a product that fits your application like no other solution available.
As experienced cable assembly manufacturers, we know the many advantages of using custom solutions in your application. Here are some of the many ways customization can benefit your application:
Additionally, other benefits you’ll reap with cable assembly manufacturing include:
Have questions? We’re ready to answer them. Be sure to contact us today and we will discuss specifics with you or get started on your custom cable manufacturing project.
There are plenty of design specifications to consider when manufacturing the highest quality cable assemblies for your application. This can include:
Numerous industries can greatly benefit from custom connectors and assemblies, especially fields that need these products to continuously perform in harsh environments. iCONN Systems is proud to provide custom solutions to accommodate fields such as:
Not seeing your industry listed? That’s not a problem because, as your team of custom cable manufacturers, we are ready to accommodate any specialized application, so reach out to us for more information on how we can best assist you.
Yes, custom connectors and assemblies can be designed to meet current and future application or infrastructure requirements. This includes customized solutions for your industry that accommodate technological advancements, expansion plans, and more, ultimately saving your business time and resources in the long run.
The total time to manufacture custom coax cables and other assemblies can depend on the complexity of the design and the method of production. With that in mind, it can take anywhere between several days to weeks to finalize the product.
For more information about the timeline of your next project, feel free to reach out to our team of cable assembly manufacturers to request an initial consultation.
iCONN Systems provides custom-designed, application-specific connectors and cable assemblies. We understand that off-the-shelf products can limit your designs, and that not all applications are the same.
Then let iCONN walk you through the process to develop the product that fits your budget and application. Fill out the form to the right to request a consultation today.
Find the right configuration and download 3D CAD files today
Evan Freemon is a highly effective Sales/Account Manager at iCONN Systems, known for surpassing sales targets and building lasting client relationships. With over two years at iCONN, he excels in identifying growth opportunities and delivering top-notch customer service, driving both business growth and client success.
iCONN Systems, LLC is a custom engineered interconnect solutions design company that focuses on the manufacturing of electrical and electronic connectors, overmolded and discrete cable assemblies and value added turnkey products.
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