CONNIXTECH develops custom waterproof cable assemblies for industrial automation, electric vehicles, energy systems, outdoor lighting, robotics and other equipment exposed to moisture, dust, vibration or demanding installation conditions. Each assembly is built around the electrical, mechanical and environmental requirements of the equipment.
What Is a Custom Waterproof Cable Assembly?
A waterproof cable assembly integrates the cable, connectors, contacts, seals, wiring, strain relief, overmolding and identification into one controlled component. Waterproof performance depends on the complete assembly, especially the connector interface and cable-entry structure.
Customization Options
- Connector family, size and locking method
- Male or female, cable-side or panel-side configuration
- Contact count and pin-to-pin wiring
- Rated voltage, current and signal requirements
- PVC, PUR, TPE and application-specific cable materials
- Wire gauge, shielding, twisted pairs and grounding
- Overall length, branch lengths and connector orientation
- Overmolding, potting, cable glands and strain relief
- Labels, sleeves, wire colors and packaging
Single-Ended, Double-Ended and Multi-Branch Harnesses
A cable assembly can be terminated at one end for integration into the buyer’s equipment, fitted with connectors at both ends, or designed as a multi-branch harness connecting several devices. Branch layouts should define each connector, cable length, wire identification and routing direction on the approved drawing.
Applications
- Battery, charging and motor harnesses for e-bikes and electric motorcycles
- Sensor and actuator cables for industrial automation
- Power and control harnesses for outdoor LED and grow lights
- Battery and control connections for energy-storage equipment
- Cable assemblies for AGVs, mobile robots and outdoor machines
- Power-distribution and signal connections for renewable-energy equipment
How the Customization Process Works
- Requirement review: define the equipment, electrical data, environment, installation and quantity.
- Configuration proposal: select the connector, cable, sealing and strain-relief structure.
- Drawing confirmation: approve dimensions, pinout, tolerances, wire colors, labels and materials.
- Prototype sampling: build samples for installation and functional review.
- Validation: perform the agreed electrical, mechanical, waterproof and dimensional checks.
- Production: manufacture against the approved drawing and inspection requirements.
Recommended Information for a Fast Quotation
Please provide the application, required IP rating, voltage, current, contact count, pinout, connector gender, panel or cable mounting, cable material, wire gauge, cable length, drawings or reference photos, estimated quantity and required delivery schedule.
If the design is still at an early stage, CONNIXTECH can begin with equipment photos, interface dimensions and a functional description. Read our detailed waterproof cable customization guide for a complete checklist.
Prototype and Quality Considerations
Depending on the project, validation may include continuity, insulation resistance, dielectric strength, contact resistance, pull force, waterproof testing, bending, mating and dimensional inspection. The applicable standards and acceptance criteria should be agreed before production.
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Start your custom cable assembly project: send your drawing, specifications and estimated quantity for engineering review and quotation.
Waterproof Connector & Cable Assembly FAQ
Clear answers for engineers and purchasing teams evaluating custom waterproof interconnect solutions.
Standard connector samples can usually start from 1 piece, and low-volume trial orders are welcome. The production MOQ depends on the connector model, cable specification, overmolding, tooling and packaging requirements. Send us your estimated quantity and specifications, and we will confirm the most practical MOQ.
Samples using standard connectors and available materials normally take about 3–7 working days. Customized pinouts, cable structures or overmolded assemblies typically require 7–15 working days after the drawing is approved. Projects requiring new tooling will receive a separate development schedule.
Our process covers six steps: requirement review, engineering proposal, quotation, drawing and pinout approval, prototype production and validation, then mass production. Please provide the application, voltage, current, contact count, IP rating, cable type, wire gauge, length, mating interface and expected annual quantity.
Testing is performed on the complete mated connector or cable assembly. Depending on the project, validation can include air-leak or pressure-decay testing, immersion testing, and electrical checks before and after exposure. Because IPX8 conditions depend on the agreed water depth and duration, the exact criteria are confirmed on the approved specification. Test reports can be supplied when requested.
Our manufacturing is managed under an ISO 9001 quality system. Depending on the connector series and target market, supporting compliance documents may include UL, CE, TÜV, CQC, CCC and RoHS. Certification scope varies by model, material, cable and configuration, so we verify the applicable certificate and report before order confirmation.
Quality control includes incoming-material inspection, first-article confirmation, in-process checks, 100% continuity and polarity testing, plus appearance and dimensional inspection. Additional waterproof, insulation, withstand-voltage, contact-resistance or pull-force tests are arranged according to the approved control plan. Typical production lead time is about 10–25 working days after sample approval and order confirmation, subject to quantity, tooling and material availability.