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Every piece of hardware — from a factory sensor to a consumer gadget — depends on cables to move power and data between components. But "cable assembly" isn't one product; it's a family of very different builds, each suited to a different connector, environment, and current or data load.
Picking the wrong type early in a design usually shows up later as a field failure, a re-spin, or a scramble to find a second vendor. This guide walks through the 11 cable and wire harness types NextPCB manufactures, what each one is actually good for, and how to move straight from "which type do I need" to a quote.
If you already know what you're building, skip the guide and configure your cable assembly directly — the quotation tool covers all 11 types below, from a 1-piece prototype to full production volumes.
1. D-Sub Cable Assemblies
D-Sub (D-subminiature) connectors are the trapezoidal, multi-pin connectors still widely used in industrial equipment, test instruments, and legacy RS-232/RS-422 serial links. They're valued for their mechanical locking screws, which keep the connection secure in equipment that vibrates or gets handled often.
Best for: industrial control panels, test & measurement equipment, legacy serial interfaces, panel-mount applications.
Read the full D-Sub cable assembly guide →
2. FFC (Flat Flexible Cable)
FFCs are thin, flat, flexible ribbon cables used to connect components inside tight, low-profile enclosures — think camera modules, displays, and printer heads. Their low height and flexibility make them ideal where a round cable simply won't bend the way the design needs it to.
Best for: displays, cameras, printers, compact consumer electronics with tight internal routing.
Compare FFC vs. IDC vs. Terminal Cable in the full guide →
3. IDC Cable Assemblies
IDC (insulation displacement connector) assemblies terminate ribbon cable without stripping individual wires — the connector's contacts pierce the insulation directly. That makes IDC harnesses fast and consistent to produce in volume, which is why they're a staple in board-to-board and board-to-panel connections.
Best for: internal PCB-to-PCB links, embedded systems, mass-produced electronics needing consistent termination.
Compare FFC vs. IDC vs. Terminal Cable in the full guide →
4. RF Coaxial Cable Assemblies
RF coaxial assemblies carry high-frequency signals with controlled impedance and shielding to minimize signal loss and interference. NextPCB supports the connector families most commonly specified for RF work — SMA, SMB, SMC, BNC, MCX, and MMCX — so the assembly matches your RF front-end without a redesign.
Best for: wireless modules, antennas, telecom equipment, RF test setups, GPS and IoT radios.
Read the full RF coaxial cable assembly guide →
5. USB Cable Assemblies
USB assemblies handle both data and power in a single cable, which is why they show up everywhere from consumer peripherals to embedded charging circuits. Custom USB harnesses let you set the exact length, connector type, and shielding your enclosure design needs — something off-the-shelf USB cables rarely match.
Best for: consumer electronics, embedded systems with USB data/power delivery, peripheral devices.
Read the full USB cable assembly guide →
6. Power Cable Assemblies
Power assemblies are built around current-carrying capacity: wire gauge, insulation, and connector contact rating all get selected to match your load safely, with margin for heat. These range from low-voltage internal harnesses to heavier-gauge assemblies for higher-current equipment.
Best for: power supplies, motors, battery packs, industrial equipment with significant current draw.
Read the full power cable assembly guide →
7. Terminal Cable Assemblies
Terminal cable assemblies connect wires directly to board headers or other wires using crimped terminals — a flexible, low-cost way to interconnect components that don't need a full connector housing. They're a common choice inside enclosures where routing needs to stay compact.
Best for: internal board-to-wire connections, sensor wiring, general-purpose interconnects.
Compare Terminal Cable vs. FFC vs. IDC in the full guide →
8. EU Industrial (M-Series) Cable Assemblies
Built around the M8, M12, M16, M23, and M40 connector standards common in European industrial automation, these assemblies are designed for factory-floor durability — vibration resistance, secure locking, and (depending on the build) sealed housings for washdown or outdoor environments.
Best for: factory automation, sensors and actuators, industrial robotics, machine-to-machine wiring.
Read the full EU industrial (M8/M12/M16/M23/M40) guide →
9. Waterproof Cable Assemblies
When equipment lives outdoors or near moisture, a standard cable assembly isn't enough. NextPCB's waterproof assemblies use sealed connectors and insulation rated to IP65, IP67, or IP68, protecting against dust ingress and water exposure at the level your application demands.
Best for: outdoor equipment, marine electronics, agricultural and environmental sensors, washdown-rated machinery.
Read the full IP65/IP67/IP68 waterproof cable assembly guide →
10. Ethernet Cable Assemblies
Custom Ethernet assemblies deliver networking and data connectivity where standard patch cables don't fit the enclosure, length, or connector orientation needed. They're commonly built alongside industrial and IoT hardware that needs a reliable wired data link.
Best for: networked industrial equipment, IoT gateways, embedded systems needing wired Ethernet.
Read the full Ethernet cable assembly guide →
11. Audio Cable Assemblies
Audio assemblies carry analog or digital signal connections for equipment where clean, low-noise audio transmission matters — from consumer audio gear to embedded devices with onboard sound.
Best for: consumer audio equipment, embedded sound systems, signal-sensitive electronics.
Choosing the Right Cable Assembly for Your Project
A few questions usually narrow it down fast:
- What's it connecting? Board-to-board, board-to-panel, or device-to-device changes which connector families make sense.
- What's running through it — data, power, or both? RF and Ethernet need controlled impedance; power assemblies need the right gauge and contact rating.
- What environment will it live in? Indoor and low-stress applications rarely need the sealing that outdoor or industrial equipment requires.
- What volume are you at? The same platform that validates a 1-piece prototype can scale straight into production, so there's no need to switch vendors between stages.
If you're not sure which type fits, NextPCB's engineering team reviews every submitted spec and verifies connector mating against your BOM before production starts — so mismatches get caught before parts are cut, not after.
Frequently Asked Questions
How do I know which cable assembly type my product actually needs?
Start from what the cable connects (board-to-board, board-to-panel, or device-to-device) and what it carries (data, power, or both). From there, environment (indoor vs. outdoor, vibration, moisture) and production volume narrow it further. If you're still unsure after reading a type's guide, NextPCB's engineering team reviews your spec and BOM before production to confirm the right fit.
Can I mix multiple cable assembly types in one order?
Yes. Many products need several types in the same build — for example, an internal FFC connection to a display alongside an external USB port and a D-Sub panel connector. These can be quoted and produced together, and optionally integrated directly into a turnkey PCBA order.
What's the minimum order quantity for a custom cable assembly?
1 piece, across all 11 types. The same online quotation platform and production process scales from a single prototype to full production volumes, so there's no need to switch vendors as the project matures.
Do I need to provide a formal drawing to get a quote?
No — the guided online quotation tool walks you through cable type, connector selection, wire gauge, insulation, and length step by step. If you already have a drawing or BOM, you can submit it for engineering review instead.
Can cable assemblies be integrated into my PCBA order?
Yes. Cable termination, connector mating, strain relief, and routing can be handled in the same production run as a turnkey PCBA order, which reduces the amount of post-assembly integration work on your end.
Get Your Custom Cable Assembly Quote
All 11 cable and wire harness types above are available through NextPCB's guided online quotation platform — configure your cable type, connectors, wire gauge, insulation, and length, and get pricing without back-and-forth emails.
- Minimum order quantity: 1 piece
- No maximum order quantity — the same platform scales into production
- Workmanship standard: IPC/WHMA-A-620
- Optional integration into your turnkey PCBA order — termination, connector mating, strain relief, and routing handled in the same production run
Start Your Cable Assembly Quote →
Already have questions about connector compatibility or lead times? Contact our team or browse the Cable Assembly Services page for full capability details. You can also return to the NextPCB homepage to explore our full range of PCB, PCBA, and cable assembly services.
