Comprehensive Cable & Wire Harness Assembly Services in Illinois
We specialize in cable assembly services and wire harness solutions, providing precise and reliable assemblies tailored to your needs. Based in Illinois, our team delivers top-notch craftsmanship and meticulous attention to detail on every project. From design to delivery, we are your trusted partner for top-notch cable assembly services.
We provide cable & wire harness assembly and cable assembly services in Illinois, offering flexible and reliable solutions tailored to meet the needs of various industries. We handle everything from design to production with a focus on quality and precision. From simple assemblies to complex harnesses, our team provides reliable solutions designed to meet your specific needs.
Custom
Wire
Harness
Multi
Conductor/
Pair
5+
Quality
Checks
Our Capabilities in Cable & Wire Harness Assembly
Custom Cable Assembly
We specialize in custom cable harness assemblies, designing and manufacturing solutions tailored to your unique specifications, ensuring high performance, reliability, and seamless integration for your applications.
Wire Harness Manufacturing
Our expert team delivers top-quality wire harness manufacturing services, focusing on precision, durability, and efficiency to meet the exact needs of your projects across various industries.
Integration with PCB Assemblies
We provide seamless integration of PCB assemblies with cable and wire harnesses, ensuring compatibility, enhanced functionality, and streamlined manufacturing for complex electronic systems.
Our Cable & Wire Harness Assembly Process
Our cable and wire harness assembly process includes design, prototyping, production, and rigorous testing, ensuring precision, quality, and reliability at every stage to meet your specific project requirements.
Design Consultation & Material Selection
Our experts provide in-depth wire harness design consultation, helping you choose the right materials and specifications to ensure your product is reliable, efficient, and perfectly suited to your needs.
Prototyping and Testing
We create prototypes and conduct thorough testing to validate functionality, durability, and performance, ensuring your final cable and wire harness solution meets the highest quality standards
Precision Manufacturing
Using advanced techniques, we specialize in precise wire harness manufacturing and cable wire manufacturing, delivering high-quality assemblies that meet exact specifications for various applications.
Rigorous Testing and Quality Assurance
Every assembly undergoes strict testing and quality assurance processes, guaranteeing that each product meets industry standards and exceeds your expectations for performance and durability.
Tech Sheet
Technology | Standard Technology | Advanced Technology |
|---|---|---|
Maximum Panel Size | 12"X18"Length | 22"X18"Length |
Maximum Board Thickness | 5MM | 5.8MM |
Minimum Edge of panel to Component for single side panels
(Panel mostly like be V-scored) | 0.5MM | 0.4MM |
Minimum Edge of panel to Component for Double side panels
(Panel mostly like be V-scored) | 0.75MM | 0.5MM |
Screen Printer accuracy | 0.2MM | 0.08MM |
SMT Placement accuracy | 0.05MM | 0.025MM |
Smallest component package size | 01005 Imperial (0402 Metric) | 008004 Imperial |
Reflow Profile method and equipment | KIC PROFILER | KIC PROFILER |
SPI Capability | 3D SPI Inline with SPC reporting | 3D SPI Inline with SPC reporting |
Component Lot/date code traceability process | all receiving is tracked under the ERP and saved in cloud | all receiving is tracked under the ERP and saved in cloud |
Lot Tracebility | Online portal, Muliple Manufacturing Lots with full tracebility to individual Mo thru the ERP. | Online portal, Muliple Manufacturing Lots with full tracebility to individual Mo thru the ERP. |
Cut and Shrink Tubing | 6 Awg-24 Awg | 2 Awg-30 Awg |
Tinning and Soldering | Tinning and Soldering | Tinning and Soldering |
Wire Crimping and Braiding | Wire Crimping and Braiding | Wire Crimping and Braiding |
Minimum Panel Size | 3"X3" length | 2.5"x 3" length |
Gallery
01
Quick and Affordable
We provide fast and cost-effective cable wire harness assembly services without compromising quality, ensuring your projects stay on schedule.
02
Top-Class Customer Service
Our team is committed to delivering exceptional customer support, ensuring your experience with us is smooth, responsive, and hassle-free from start to finish.
03
End-to-End Solutions
From design and prototyping to production and testing, we handle every step of the cable wire harness assembly process, giving you complete and reliable solutions.
04
Custom Quotes & Production
We offer tailored quotes and scalable production options, making it easy to adapt our services to your specific project needs and timeline.
05
Material Selection
Material selection is essential for compatibility, durability, and performance under varying environmental conditions and operational requirements.
06
Assembly and Integration
Skilled technicians execute a precise cable and wire harness assembly process, including cutting, stripping, crimping, and soldering, to integrate components seamlessly and ensure robust electrical connections.
07
Inspection and Testing
Testing and quality control for cable assembly services measures verify adherence to specifications and standards, guaranteeing reliability, safety, and performance before deployment.
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FAQ's
A2Z EMS offers a wide range of assemblies, including custom wire harnesses, multi-conductor cables, ribbon cables, overmolded assemblies, and integration-ready solutions for PCB connections. We tailor every assembly to meet the electrical, mechanical, and environmental needs of your application.
Yes, we specialize in fully custom cable and wire harness assemblies. Our team works with your drawings or assists in the design process to deliver solutions that match your exact technical and functional requirements.
Absolutely. Whether you need a one-off prototype or bulk production, A2Z EMS is equipped to scale based on your project demands while maintaining consistent quality and delivery timelines.
We serve a wide array of industries, including automotive, aerospace, healthcare, telecommunications, industrial automation, and consumer electronics. Our assemblies are built to meet the specific durability, safety, and compliance standards of each sector.
Yes, we provide rapid prototyping services to help validate your design before committing to full-scale manufacturing. This ensures proper fit, function, and manufacturability.
Every assembly undergoes rigorous inspection and testing, including continuity tests, pull tests, and visual inspections. We follow strict quality assurance protocols to ensure each unit meets customer and industry specifications.
Yes, our cable and wire assemblies are RoHS and REACH-compliant. We also use traceable materials and components, ensuring environmental and regulatory compliance for global applications.
Costs vary depending on factors like cable type, length, connector types, complexity, and order volume. We provide competitive pricing and detailed quotes tailored to your specific project. Get in touch with our team right away!
Our Pricing is influenced by several elements, including:
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Design complexity
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Material and component selection
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Assembly processes (e.g., soldering, overmolding)
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Volume and turnaround time
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Testing requirements
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Yes, we offer volume-based discounts for larger orders. The more you order, the more cost-effective it becomes, making A2Z EMS an ideal partner for scalable manufacturing.
Lead times depend on the project size and complexity, but typical orders are fulfilled within 7–15 business days. Expedited services may be available for urgent needs.