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How Are Cable Assemblies Manufactured?

Cable assemblies are fundamental components that power, connect, and ensure the functionality of a wide range of devices across various industries, including Industrial Automation, Aviation Simulation, and Safety Systems.

These assemblies are more than just a bundle of wires; they are meticulously designed and manufactured systems that meet specific electrical and mechanical requirements.

Here, we take a closer look at the sophisticated process behind the manufacture of cable assemblies, highlighting the precision and expertise Tenkay brings to each step of the process.

Step 1: Design and Prototyping

The manufacturing process begins long before any physical work is done on the cable assemblies.

It starts with a thorough design phase where the application's specific needs are assessed.

This involves determining the electrical requirements, environmental conditions, and mechanical constraints of the assembly.

Prototyping follows the design phase, where initial samples are produced for testing and validation, ensuring the design meets all operational requirements.

Some of our clients ask us to make them a prototype; others make their own in-house and just require our manufacturing services. We can accommodate whichever process works best for you.

Step 2: Pre-Production

Once the design is finalised, the manufacturing process moves on to cutting and stripping the wires.

Precision machinery is used to cut wires to the exact length required by the design specifications.

The insulation is then stripped from the ends of each wire, preparing them for termination.

This step is meticulously controlled to ensure the integrity of the wire is not compromised.

At Tenkay, we automate this process wherever possible to achieve consistency and quality over volume.

Step 3: Termination

Termination involves attaching connectors or terminal blocks to the stripped ends of the wires.

This can be done manually for complex assemblies or through automated processes for higher volumes.

The choice of termination method depends on the cable assembly's design and the application's specific requirements.

Tenkay uses high-quality connectors and employs skilled technicians to ensure a secure and reliable connection.

Step 4: Assembly

With all components prepared, the assembly process begins.

This can involve simply grouping wires into a single sheath or more complex configurations with multiple branches and connections.

Tenkay’s manufacturing staff carefully follow the design schematics to bundle, route, and secure the wires and components, ensuring that the final product meets both the physical and electrical specifications outlined in the design phase.

Step 5: Testing and Quality Assurance

The final and perhaps most critical step in the manufacturing process is testing and quality assurance.

Where applicable, Tenkay conducts comprehensive electrical tests to ensure the assembly performs as intended, including continuity tests, insulation resistance tests, and high-voltage tests.

Our operatives can also carry out physical inspections to ensure the assembly meets all mechanical requirements.


Manufacturing cable assemblies is a complex process requiring design, material science, and engineering expertise.

At Tenkay, we pride ourselves on our meticulous attention to detail at every stage of the manufacturing process.

Our commitment to quality and reliability ensures that our cable assemblies meet the demanding requirements of the industries we serve, giving our clients the confidence that their operations are powered by the best possible connections.

Find out more about our cable assemblies service or contact our team via any of the methods below.