Onset Engineering(949) 446-9456

CABLE ASSEMBLIES

Cable assemblies and wire harnesses.

One Irvine shop designs the enclosure, 3D-prints or molds the housing, overmolds the connector and strain relief, and builds and 100% electrically tests the cable harness and the electromechanical box. Prototype through production, without a high minimum. ITAR registered.

Send a schematic, wire list, pinout table, BOM, PDF drawing, STEP, STL, 3MF, or SolidWorks file. A physical sample cable or part is enough to reverse-engineer and replicate.

Email for a quoteMedical connectors
A coil of gray overmolded multi-pin circular cables with part labels, on a table in front of the Onset Engineering wall sign.
Overmolded circular cables
A multi-branch wire harness on a wood bench, with circular metal backshells, a ribbon breakout, and crimped and ferrule terminations.
Multi-branch wire harness

WORKMANSHIP

Built to the cable standards.

Assemblies are built to IPC/WHMA-A-620 and J-STD-001 workmanship standards.

Onset Engineering is ITAR registered. Materials and finishes are RoHS and REACH compliant.

A technician in safety glasses soldering a wire assembly held in a bench vise, with white enclosures on the table.
Soldering a cable assembly

TESTING

Every cable is tested.

100% electrical testing on Cirris CH2 high-voltage analyzers. Hipot and insulation resistance run up to 1500 VDC / 1070 VAC, with 4-wire Kelvin low-resistance measurement.

SOLIDWORKS Electrical covers harness routing, 2D nailboard drawings, BOM generation, and the rest of the cable documentation.

Close-up of a Cirris CH2 cable analyzer, with interface cards, scanner connectors, and red test leads plugged into the base.
Cirris CH2 cable analyzer
A 3D-printed cable test fixture with an LCD pin readout, a probe on a connector, and a lit fiber lead.
Printed cable test fixture

OVERMOLDING

The connector and the strain relief.

Custom strain relief and connector overmolding are done in the same shop as the harness.

A sample cable can be reverse-engineered and replicated when a drawing does not exist yet.

A blue 3D-printed connector housing, with NOVALINK molded into the cover, on a coiled black harness with green terminal connectors.
Printed connector housing and harness

APPLICATIONS

Connectors, harnesses, and box builds.

LEMO and other push-pull circular connectors, RF and coaxial cable, D-sub, multi-pin circular, ribbon and flat cable, and power cable.

Medical device cables and connectors for MRI, surgical robotics, and patient monitoring. Defense, aerospace, UAV, and drone wire harnesses.

Complete electromechanical box builds and terminal-block subassemblies, from a prototype quantity through production.

A hand holding a circular multi-pin connector, with a pinout sketch on the bench behind it.
Circular connector pinout
A D-sub connector backshell open during assembly, with color-coded wires clamped inside.
D-sub backshell assembly

PROCUREMENT

Company identifiers.

CAGE 8JQH9 · D-U-N-S 117469491 · UEI FTY1P8U29NS9 · Small Business ID 2024131

NAICS 335931, 334419, 335929, 335999, 541330, 541420

A wired terminal-block harness with red, black, white, and green leads.
Wired harness
An engineer at a white bench soldering a wired assembly under a task lamp, with power supplies and hand tools beside the work.
Soldering on the bench
A batch of identical green terminal-block assemblies with red, black, and white wires, laid out on a workbench.
Terminal-block assemblies
Green terminal blocks mounted in a black enclosure, wired with red and black leads and marked with white labels.
In an enclosure