Terminated cables and wire harnesses for sensors, equipment and electronics · Connector interface and coding, contacts and plating, cable construction, overmoulding and IP rating, crimp pull strength, bend radius, and continuity, dielectric withstanding voltage and insulation resistance testing
A connector cable assembly is a length of cable or a bundle of wires terminated at one or both ends with connectors — crimped, soldered or moulded on — and tested as a unit, so that a sensor, board or machine can be plugged in rather than wired on site; a wire harness is the multi-branch version that routes multiple circuits through one assembly. Ask three things first: which connector interface, coding and pinout each end must mate with, what current, voltage, signal and environment the cable must carry and survive, and which workmanship standard and electrical tests the assemblies must pass.
Electrical cable assemblies and wire harnesses built to drawing: sensor and actuator cables (M8, M12), wire-to-board and wire-to-wire harnesses, I/O and data cables, and coaxial RF cable assemblies, with their terminations and tests. Bare connectors, bulk cable, fibre-optic patch cords, waveguide assemblies and automotive main harness design are outside this page except where compared.
01
Fleconn's M12 4-pin male-to-female cable shows how a sensor cable assembly is specified. It cites IEC 61076-2-101 as its reference standard, with an A-coded interface (2 power and 2 data pins), rated current 4 A, rated voltage 250 V, impulse voltage 600 V, contact resistance ≤5 mΩ and insulation resistance ≥20 MΩ, unshielded, with an M12 × 1.0 mm screw lock tightened at 1.0 N·m recommended and 1.2 N·m maximum. Male pins are brass and female contacts phosphor bronze, gold-plated, in a glass-filled PA66 insert under a black TPU overmould, with a nickel-plated brass nut and an FKM O-ring. [1]
The cable is UL AWM style 2464 with stranded tinned copper conductors of 20 AWG and 26 AWG, a PVC or PUR sheath of about 4.0–5.2 mm outside diameter, and lengths of 1, 2 or 3 m ±50 mm including the connectors; the assembly is rated IP67/IP68 and for −40 to 80 °C static and −25 to 80 °C in motion. The same maker says the M12 4-pin cable can be built with A, B, D, L, K, S or T-coded connectors — the coding decides which mating parts and which uses (sensor, fieldbus, Ethernet or power) the cable fits. [1]
NASA-STD-8739.4A, the agency's workmanship standard for crimping, interconnecting cables, harnesses and wiring, requires wires leaving connectors to be stress-relieved (backshells, encapsulation or boots), crimped contacts to be used only with stranded wire, harnesses to be protected where they pass sharp or rough edges, and the lay length of twisted layers to be 8 to 16 times the harness diameter; it discourages splices and bans them within two harness diameters of a breakout. [2]
Give the supplier the drawing or schematic with pinout for each end, connector part numbers or interface and coding, contact plating, cable type (conductor size, shielding, sheath material, UL style), length and tolerance, overmould or backshell, IP rating and temperature, flexing or drag-chain duty, labels, packaging and quantities.
02
NASA-STD-8739.4A requires every cable assembly to pass continuity, dielectric withstanding voltage (DWV) and insulation resistance (IR) tests, in that order. Its DWV test applies 1,050 ± 50 V RMS at 60 Hz, 1,500 ± 75 V DC, or the hi-pot voltage in the connector, cable or wire data sheet, whichever is least, for at least 5 seconds between each conductor and all others, the connector bodies and shields, with leakage not above 1 mA; IR is measured at 500 V DC and must exceed 100 MΩ. Coaxial assemblies get continuity, isolation, DWV, insertion loss, VSWR and time-domain reflectometry tests as the engineering documents specify. [2]
For crimps, the standard pulls sample contacts at 25.4 ± 6.3 mm per minute and sets minimum crimp tensile strengths by copper wire gauge — for example 22 N at 28 AWG, 57 N at 22 AWG, 142 N at 18 AWG and 290 N at 14 AWG — or at least 60% of the wire's tensile strength for sizes not listed, with pull tests at the start and end of each shift or production run. [2]
Its bend-radius table for completed cables and harnesses gives a minimum of 6 × outside diameter (10 × optimum) for individual coaxial cable, 3 × OD for an overall harness of AWG 10 or smaller without coax, and 10 × OD (15 × optimum) where polyimide-insulated wire is present. [2]
Editorial calculation: for the 5.2 mm maximum-diameter M12 cable above, NASA's 3 × OD harness minimum would be about 16 mm and its 10 × OD optimum about 52 mm; where the cable flexes in service, ask the cable maker for its own dynamic bend radius rather than using these static figures. [2] [1]
Editorial note: NASA-STD-8739.4A was written for space flight hardware. Commercial orders may instead call up IPC/WHMA-A-620 or the customer's own drawing; name the standard and class in the order, and ask for the test report per lot.
03
The eight supplier cards below split by build type: M5 to M16 and 7/8-inch sensor cables (Fleconn); JST, Molex and Fakra harnesses (Cloom Tech, EcoCables); D-sub, HDMI and USB I/O cables (Extending); connector cable assemblies (Fuyconn); RF coaxial assemblies (Dosin, Leader Microwave); and cable assembly as an electronics manufacturing service (Auspi).
04
The US Federal Aviation Administration's Advisory Circular 43.13-1B gives harness rules a buyer can copy onto a drawing. Bends in wire groups or bundles must be no tighter than 10 times the outside diameter of the largest wire, or six times at breakouts or reversals if suitably supported; RF cables should not bend tighter than six times their outside diameter. Wiring at terminal lugs or connectors should have enough slack for two reterminations without replacing wires, and bundle supports such as clamps should be spaced at no more than 24 inches. [3]
On splices, the circular says there should not be more than one splice in any one wire segment between two connectors or other disconnect points (with listed exceptions), splices in bundles must be staggered, and splices should not be used within 12 inches of a termination device except in named cases. It adds that the tensile strength of a wire-to-terminal joint should be at least equal to that of the wire, and that no more than four terminal lugs, or three lugs and a bus bar, should go on any one stud. [3]
For identification, the circular places markings at each end of a wire and at 15-inch maximum intervals, centres the marking on wires 3 to 7 inches long, and marks individual wires inside a cable within 3 inches of their termination. As good practice it suggests two spare contacts on connectors with 25 or fewer contacts, 4 spares for 26 to 100 contacts and 6 spares above 100, with every contact cavity filled and unwired contacts sealed with a plastic grommet plug. [3]
05
The NASA and FAA bend rules above cover static harnesses. For a cable assembly that moves in an energy chain, igus ties the minimum bend radius of its chainflex CF9 TPE control cable to temperature and to the number of double strokes it guarantees. Between −25 and +90 °C it gives 5 × d for 5 million, 6 × d for 7.5 million and 7 × d for 12.5 million double strokes; at −35 to −25 °C and at +90 to +100 °C the factors rise to 6.8, 7.5 and 8.5 × d. The page states that higher stroke counts are possible through its service-life calculation. [4]
igus describes the CF9 for unsupported travel and gliding travel of up to 400 m or more, and lists resistance to oil, including bio-oils, coolant and UV. [4]
Editorial calculation: for the 5.2 mm maximum-diameter M12 cable described above, 7 × d is 36.4 mm and 8.5 × d is 44.2 mm. Those are igus CF9 factors, not values for a PVC or PUR sensor cable; ask your supplier for the minimum bend radius, stroke count and temperature band of the exact cable, and for the test that supports them.
| Temperature band (°C) | Double strokes guaranteed | Minimum bend radius (× outer diameter) |
|---|---|---|
| −25 to +90 | 5 million / 7.5 million / 12.5 million | 5 / 6 / 7 |
| −35 to −25 | 5 million / 7.5 million / 12.5 million | 6.8 / 7.5 / 8.5 |
| +90 to +100 | 5 million / 7.5 million / 12.5 million | 6.8 / 7.5 / 8.5 |
06
The Fleconn M12 cable supplies the materials for the first five rows: gold-plated brass and phosphor-bronze contacts in a glass-filled PA66 insert, a TPU overmould, a nickel-plated brass nut and an FKM O-ring. [1]
| Part | Role | Fix in the order |
|---|---|---|
| Connector insert and housing | Holds the contacts in the mating interface. [1] | Interface, coding, pin count. |
| Contacts | Carry current and signal. [1] [2] | Material, plating, crimp or solder. |
| Cable | Carries the conductors between ends. [1] | Gauge, cores, shield, sheath, UL style. |
| Overmould or backshell | Seals and relieves strain at the exit. [1] [2] | TPU, PVC or metal backshell; IP rating. |
| Coupling nut and O-ring | Locks and seals the mated pair. [1] | Thread, torque, seal material. |
| Shield termination | Carries the screen through the connector. [2] | Shield type and termination method. |
| Labels and sleeving | Identify and protect the run. [2] | Marking, protection over edges. |
07
The values come from one M12 cable and NASA-STD-8739.4A's acceptance limits; on an order, the standard and class named on the drawing decide which limits apply. [1] [2]
| Field | What it means and published values | Ask the supplier for |
|---|---|---|
| Number of contacts | 4 pins (2 power + 2 data) on one M12 A-coded cable. [1] | Pinout drawing per end. |
| Contact resistance (mΩ) | ≤5 mΩ on one M12 cable. [1] | Value and test method. |
| Insulation resistance (MΩ) | ≥20 MΩ on one M12 cable; >100 MΩ at 500 V DC acceptance in NASA-STD-8739.4A. [1] [2] | Test voltage and limit. |
| Dielectric withstanding voltage | 1,050 V RMS, 1,500 V DC or the data-sheet hi-pot, whichever is least; ≤1 mA leakage. [2] | Hi-pot level and duration. |
| Rated current (A) / voltage | 4 A, 250 V, 600 V impulse on one M12 cable. [1] | Rating at your temperature. |
| Operating temperature (°C) | −40 to 80 °C static, −25 to 80 °C dynamic on one M12 cable. [1] | Static and flexing ratings. |
| IP rating | IP67/IP68 on one M12 cable. [1] | Mated or unmated rating. |
| Cable gauge | 20 AWG and 26 AWG in one cable; crimp pull minimums from 22 N (28 AWG) to 290 N (14 AWG). [1] [2] | Gauge and crimp pull data. |
| Cable length (m) | 1, 2 or 3 m ±50 mm including connectors on one range. [1] | Length and tolerance. |
| Contact plating | Gold on one M12 cable. [1] | Plating type and thickness. |
| Mating cycles | Ask: not stated in the reviewed sources. | Rated mating cycles. |
08
Paste it into your enquiry below or into an email to a maker, then replace every bracket.
Ends: [connector interface; coding; pin count; part numbers] Cable: [cores; AWG; shield; sheath; UL style; length] Circuit: [current; voltage; signal type] Environment: [IP rating; temperature; flexing; chemicals] Workmanship and tests: [standard and class; continuity; hi-pot; IR] Supply: [labels; packaging; quantity; samples]
12 companies list this product among what they make. Company figures are quoted from each company's own website; every card states where the relationship came from.
Lists M5, M8, M12, M16 and 7/8-inch connector cable assemblies, custom overmoulded cable assemblies and wire harnesses with Molex, JST, TE and Deutsch connectors.
Product scope checked 2026-10-11
Lists wire harnesses and cable assemblies, including Fakra, industrial, JST and Molex connector assemblies.
Product scope checked 2026-10-11
Lists electrical and automotive wiring harnesses, battery cable harnesses, JST wire harnesses and Molex cable assemblies.
Product scope checked 2026-10-11
Lists D-sub, DVI, HDMI, USB and telephone cable assemblies, LAN patch cords and customised cables and wire harnesses.
Product scope checked 2026-10-11
Lists connector cable assemblies alongside Centronic, DIN 41612, SCSI, V.35, IEEE-488 and SFP connectors.
Product scope checked 2026-10-11
Lists RF coaxial cable assemblies with BNC, SMA, MMCX, N, UHF, SMB, TNC and MCX connectors.
Product scope checked 2026-10-11
Lists RF cable assemblies among microwave components such as filters, couplers and amplifiers.
Product scope checked 2026-10-11
Lists cable assembly among electronics manufacturing services with PCBA and box build.
Product scope checked 2026-10-11
Explore company information and manufacturing capabilities, then discuss the scope of your project with a relevant supplier.
Continuity, then dielectric withstanding voltage, then insulation resistance; NASA-STD-8739.4A requires all three, with IR above 100 MΩ at 500 V DC, and adds insertion loss, VSWR and TDR for coaxial assemblies. [2]
NASA-STD-8739.4A sets minimum pull forces by wire gauge, such as 57 N at 22 AWG, or 60% of the wire's tensile strength for sizes not listed. [2]
The coding (A, B, D, L, K, S, T and others) keys the connector so that only compatible parts mate; one maker offers the same 4-pin cable with A, B, D, L, K, S or T coding. [1]
NASA-STD-8739.4A sets minimums of 3 × OD for an overall harness of AWG 10 or smaller wire without coax, 6 × OD for coaxial cable, and 10 × OD where polyimide-insulated wire is used. [2]
The FAA's Advisory Circular 43.13-1B says there should not be more than one splice in any one wire segment between two connectors or disconnect points, and none within 12 inches of a termination device except in the cases it lists. [3]
igus rates its chainflex CF9 control cable at 5 × d for 5 million double strokes and 7 × d for 12.5 million between −25 and +90 °C, rising to 8.5 × d for 12.5 million at −35 to −25 °C and +90 to +100 °C. Ask for the equivalent table for the cable you buy. [4]
Sources checked 2026-10-11. The Fleconn page describes one maker's sensor cable, NASA-STD-8739.4A one agency's workmanship and test rules, FAA Advisory Circular 43.13-1B aircraft wiring practice, and the igus page one maker's flexing-cable ratings; the standard, class and values for your assemblies must come from your drawing and the supplier offered.
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