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Consult Custom Cable Manufacturers for Unique Projects


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.

Examples of Custom Connectors That We Manufactured to Meet Our Clients' Specific Needs

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Designed & Built to Last


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:

  • Custom Geometry for coax, signal and power
  • Self-cleaning threads for an extremely dirty (sewer) application
  • Custom cable construction with strength members
  • Specific resins for mechanical bonding and sealing

Zero Defects in Harsh Environments


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.

Robust & Aesthetically Pleasing


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.

3D Printing for the WIN!


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.

Sealing and Connectorizing Battery Cases


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.

Sensitive Circuitry Sealed


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.

Sealed PCB Mount Connector


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.

Low Profile I/O Connector


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.

Seamless Connector Integration


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.

Cheap! and Custom


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.

Quick-Connect PCB Mount Connectors


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.

Quick Connect IP67 Connector


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.

Ready to discuss your project and custom needs?


Learn About Your Go-To Team of Custom Cable Manufacturers

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.

Custom Cable Connectors

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.

Key Elements in Our Cable Assembly Manufacturing

Mechanical Features

Design details that are specific to how cables and connectors are adjoined include:

  • Pin sequence
  • Keying
  • Locking mechanisms
  • Backshells

Connector Shape and Orientation

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:

  • Circular connectors
  • Rectangular connectors
  • Straight overmold
  • Right-angle overmold

Mount Styles

This is how a connector and cable assembly are affixed to a device (such as a computer or appliance). Options include:

  • Panel mount
  • Free-hanging mount
  • Board mount

Coupling Styles

This refers to how one connector end mechanically joins with another connector end. Options include:

  • Quick connect (plastic)
  • Snaplock
  • Threaded (metal)
  • Bayonet
  • Push-pull

Terminal Bonds

This is the method used to adjoin a wire to a wire or a wire to a terminal. Options include:

  • Crimped
  • Soldered

Wire Gauge

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:

  • 10
  • 12
  • 14
  • 15
  • 18
  • 20
  • 22
  • 23
  • 24
  • 26
  • 28

Number of Contacts

This refers to the pins and sockets found on each connector end that fit together to complete an electrical connection. Options include:

  • 2 through 12
  • 14
  • 18
  • 20

Contact Materials

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:

  • Silver alloys
  • Gold
  • Platinum
  • Carbon
  • Niobium

Insulation Materials

These are materials used to prevent an electrical current from coming into contact with other wires, equipment, or users. Options include:

  • Polyvinyl chloride (PVC)
  • Polyethylene (PE)
  • Polypropylene (PP)
  • Polyurethane (PUR)
  • Chlorinated polyethylene (CPE)
  • Nylon
  • Thermoplastic rubber (TPR)
  • Thermoplastic elastomers (TPE)

Overmolding Materials

These are materials used in an injection molding process to permanently combine a cable and connector into one single, seamless part. Options include:

  • Polyvinyl chloride (PVC)
  • Polypropylene (PP)
  • Acrylonitrile butadiene styrene (ABS)
  • Thermoplastic rubber (TPR)
  • Thermoplastic polyurethane (TPU)
  • Polybutylene terephthalate (PBT)

Get the guide: Everything You Need to Know About Overmolded Cables.

Aesthetic Properties

This refers to details that enhance the appearance, installation, and user experience of a connector and cable assembly. They include:

  • Color
  • Ergonomics
  • Specialized packaging
  • Miniaturization

Performance Properties

These are design elements that physically enhance how a connector and cable assembly performs in a specific environment or application. They include:

  • Mechanical durability
  • Extreme temperature capabilities
  • Ruggedness/strength
  • Tamper-proof properties
  • Water resistance
  • Chemical resistance

Our Process for Custom Cable Assembly

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:

  • Researching and developing a strategy – Any time we tackle a project we do our due diligence, working to fully understand the needs of our customers and developing specs that fit these demands. Through our efforts, our team of custom cable manufacturers will be able to help you find the perfect solutions.
  • Creating a custom design – After hearing customer requests and requirements, and conducting research, we present our findings, offering solutions that will fit your application. The design will be suited for manufacturability and will eliminate unnecessary variability.
  • Developing a prototype – In this step of custom cable manufacturing, we build a sample of your product. This is done using our 3D printer, which allows all specs to be created to scale. Then, we test the part for efficiency. Prototyping is essential because it allows us to work with our customers closely to identify any design improvements early in the process.
  • Manufacturing the product – Using cellular manufacturing, our team of custom cable manufacturers crafts the product from start to finish in one production cell. This form of manufacturing allows the custom cable manufacturing project to be created with smaller lot sizes, shorter lead times, consistent quality, less waste, and on-time delivery.
  • Enacting quality control measures – After the product is manufactured, our team of custom cable manufacturers will check the ISO-certified final product for defects and ensure that it meets project demands.
  • Providing support – Just because the cable assembly manufacturing process is over doesn’t mean our relationship ends. We are here to support you long term and make alterations to your products or create new ones when you require something that the market doesn’t offer.

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.

The Benefits of Custom Cable Assembly Manufacturing

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:

  • Tailored to the application – Since cable assembly manufacturing uses customization, the result is completely tailored to your application. This means that the result can accommodate unique specifications and requests that off-the-shelf cables aren’t able to.
  • Providing optimal performance – Custom cables supply the best performance in very specific environments or applications. This is especially applicable for extreme temperatures, mechanical stress, electrical interference, and weather.
  • Compliant to standards – Custom cable manufacturers are able to comply with industry standards and regulations, which means that they are ready to adhere to safety and performance standards.
  • Backed by expert technical support – Our custom cable manufacturers have years of applicable experience, meaning they can provide advice on designs, material selection, and more to help ensure that your cable meets the demands of your project.
  • Limitless design options – Product teams have a lot of flexibility when determining the best solution for their project. In some cases, a fully customized connector and cable assembly is best. In other situations, teams can save time and money by re-engineering an existing product. Either way, the best approach is to work with custom cable manufacturers with in-house engineering capabilities.

Additionally, other benefits you’ll reap with cable assembly manufacturing include:

  • Adding value and ROI
  • Improved safety profile
  • Increased product aesthetics/appeal
  • Ensuring reliability
  • Improving user experience
  • Extending shelf life
  • Lowering product costs

Incorporate Custom Cable Manufacturing into Your Next Project

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.


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.

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