Cars, industrial machinery, medical devices, and other modern electronics rely on wiring to transmit data, power, and signals between internal components and external peripherals. This wiring must be custom-built using OEM cable assemblies to ensure maximum reliability, safety, and performance. 

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This guide covers cable assembly organization options and key factors when selecting a contract manufacturer.

What Is an OEM Cable Assembly?

Original Equipment Manufacturer (OEM) parts are components produced by the same company that designs and builds the final product, rather than by a third-party supplier or subsidiary.

An OEM cable assembly is a custom-built wiring harness or cable bundle designed for a specific piece of equipment. These assemblies support specialized functions across different device sections, ensuring efficient data transmission, power, or signals.

OEMs Across Different Industries

Automotive

Modern vehicle communication and safety systems need cable assemblies that meet strict performance standards for durability, vibration resistance, and high-temperature resistance.

Telecommunications

Cable assemblies help build robust network infrastructures in communication towers and data centers. They also enable reliable, high-speed data transmission in networking equipment.

Medical

Cable assemblies in the medical field must adhere to stringent health and safety standards to ensure reliability and biocompatibility in diagnostic equipment, patient monitoring systems, portable/handheld medical devices, implants, etc.

Aerospace

Aerospace demands reliable real-time communication, navigation, and instrumentation, making Cable assemblies necessary because they maintain optimal performance despite exposure to extreme conditions.

Industrial

Cable assemblies are built to ensure these systems transmit data and signals reliably despite being exposed to extreme heat, chemicals, and physical wear.

Renewable energy 

Renewable energy systems like solar rely on cable assemblies to ensure consistent power delivery while withstanding harsh environmental conditions, including UV exposure, extreme temperatures, moisture, and corrosion.

Agriculture

Like industrial applications, agriculture is becoming more automated, meaning reliable real-time data transmission is paramount. For instance, tractors need real-time GPS data transmission to navigate the fields when ploughing.

Oil and Gas

Cable assemblies for this field are built to withstand chemicals and fire exposure, which ensures operations run smoothly even when mishaps occur.

Military and Defense

This category combines several advanced fields, such as communications and aerospace, with more demanding requirements. Cable assemblies used in military and defense applications, including aircraft, communication networks, and early detection systems, must deliver exceptional reliability, performance, and durability under extreme operating conditions.

Why Use an OEM Cable Assembly?

Although costlier than their generic counterparts, OEM cable assemblies are important for the following reasons.

Factory Certified and Guaranteed

Building cable assemblies requires the original manufacturer’s blueprints or specifications. This ensures the final product is plug-and-play and meets performance standards.

Safety

OEM cable assemblies are custom-built with safety features tailored to their specific functions. They help ensure systems operate reliably and can provide feedback when needed.

For instance, a generic battery cable assembly in a vehicle can only channel power to the electronics. But its OEM counterpart has features like fusible links for circuit protection or an EBS on the terminal to measure the battery’s temperature and voltage.

Performance in OEM Equipment Engineering

In ICE vehicles, OEM cable assemblies provide reliable real-time data transmission from various sensors in the engine and transmission to ensure efficient operation and better driving dynamics.

Cable Assembly Customization Options

Cable assemblies include wires, cables, terminals, connectors, and harnesses for specialized functions. 

Wires/Cables

The most suitable wire to use depends on several factors, which include:

• Application type: GPT/GXL/SXL for automotive, high-resistance wire, high-temperature wire, etc.
• Wire gauge: Should match the AWG standard without cheating by using thick insulation.
• Wire color: Color dies on white insulation can come off, so the best solution is to use solid-color extrusion insulation.
• Wire stripping color: Can be white, colored, or cross-colored.
• Wire and strip length: Matches the specific application.
• Insulation material type: The best insulation that maximizes durability is petroleum-based (PVC and XLPE). We avoid soy-based insulation due to rodent attraction.
• Origin: For quality purposes, only go for wires built by reputable manufacturers in the industry.

Terminals/ Connectors

We pick the matching terminals/connector type for each harness according to the OEM specifications or replace them if they are obsolete. We are also careful enough to match the connector color and material.

Lamp Sockets

We look at the design, material, and functionality for 100% matching for bulb sockets.

Grommets

The factors to consider are the grommet size, durometer, material, orientation, and color.

Clips & Clamps

Some customization options for the clip and clamp are their type, durometer, color, material, orientation, and placement.

Tape

We consider the tape color, width, type (cloth, fiberglass for high-temperature areas, adhesive, or non-adhesive), and wrapping to match the OEM cable assemblies. We also use automated machine taping to ensure uniform spacing, overlapping, and tightness.

What to Look for in an OEM Cable Assembly Manufacturer

Online Cable Assembly Configurator

An online configurator allows you to design custom OEM cable assemblies from scratch by picking components or parameters for each part. These include the cable types, materials, connectors, wire length, etc. 

The more customization options on the configurator, the more accurate the pricing estimation will be before you place an order, and the better the specification details will be provided to the manufacturer for quicker and precise production.

Parts Sourcing Capability for OEMs

Sourcing expertise is critical in this line of business because it affects production timelines, product quality, budget, and correctness. Your contract manufacturer should have a dedicated sourcing department comprising experts plus deep networks with reputable suppliers.

At Wiringo, we have built networks with quality component manufacturers to keep our supply chain as efficient as possible. But we don’t just transfer these components to our stock rooms when they arrive. They are checked against the BOM and inspected thoroughly for quality and correctness to match the required part numbers.

Advanced Manufacturing Techniques 

If the original parts have become obsolete, the contract manufacturer is supposed to have the tooling required to rebuild them according to OEM specifications. 

For example, to create the wire joint, we machine-crimp them using a 3–5 ton press and dip-solder if necessary before testing random samples using digital pull-testing machines for quality control.

Industry Certifications

OEM cable assemblies should follow established industry standards, which means your contract manufacturer must hold the appropriate certifications. Key examples include IATF for automotive quality, ISO for general quality management, and ISO for environmental compliance.

We use automated machines and robotics to streamline manufacturing and assembly, speeding up production and minimizing human error. Every step of the process is carried out with strict adherence to industry standards.

Flexible Order Quantities

Your manufacturer should offer flexible order quantities that can be adjusted based on customer demand, without significant price increases or penalties. This flexibility is important for meeting changing business needs.

We support both low and high-volume orders. Larger orders benefit from economies of scale, but smaller orders are still priced competitively. We can adjust these details and compare pricing with our cable assembly configurator.

On-Time Delivery

Product delivery on schedule will reduce customer frustrations and improve profitability and competitiveness. To check on this, ensure your manufacturer has an efficient production process, supply chain, and shipping option(s).

Our lead times are short. This is complemented by our fast shipping options globally.

Warranty

While quality control is important, you should only choose a manufacturer that offers a product warranty. This protects your business from potential financial losses caused by malfunctions or manufacturing defects.

Choose Wiringo as Your Manufacturer

OEM cable assemblies are pricier than the ones available in the gray market, but that reflects their quality and reliability.

Wiringo’s cable assemblies qualify as OEM because they are built to exact original specifications using factory blueprints. Each assembly is a precise plug-and-play reproduction, fully assembled, factory-correct, and ready to install.

What is Hydrophilic Guidewire?

A hydrophilic guidewire is a thin, flexible wire used in interventional radiology and cardiology procedures to guide catheters through blood arteries. It is hydrophilic coating, which forms a slick surface when exposed to moisture (blood or salt water), is what makes it unique. The hydrophilic coating’s lubricating properties reduce friction between the guidewire and the vessel wall, facilitating easier travel and lowering the possibility of injury to the vessel during catheterization. When a catheter is being manoeuvred inside the vasculature, guidewires are a vital source of support. The hydrophilic coating facilitates a stable insertion, improving the catheter’s control and stability.

Composition of a Guidewire:

The hydrophilic guidewire consists of two main parts:

• Core Wire:

The strength and flexibility required to manoeuvre through complex capillaries are provided by this center shaft. Materials for the core wire that are often used are:

• Stainless Steel:

Stainless steel is durable and reasonably priced.

• Nitinol:

An alloy with form memory renowned for its exceptional pushability, kink resistance, and flexibility.

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• Hydrophilic Coating:

The key to its operation is the hydrophilic coating, a specific layer that is put to the core wire. Hydrophilic plastics include:

• Polytetrafluoroethylene (PTFE):

The commonly used polymer polytetrafluoroethylene (PTFE) is renowned for having minimal friction.

• Hydrogels:

When exposed to moisture, these water-absorbent polymers form a lubricating layer.

Hydrophilic Guidewire Characteristics:

Several important qualities set these specific cables apart:

• Excellent Lubricity:

The hydrophilic coating reduces blood vessel friction for easy travel by providing remarkable smoothness.

• Increased Flexibility:

Their design places a high value on flexibility, which allows them to bend and negotiate complex capillaries without kinking.

• Fluoroscopic Visibility:

During surgeries, good vision under fluoroscopy guidance is ensured by radiopaque markers included in the guidewire.

Versatility:

To accommodate a variety of interventional procedures, hydrophilic guidewires are available in a range of lengths, diameters, and tip designs.

Applications of Guidewires:

These guidewires are extremely useful in a variety of minimally invasive treatments due to their versatility:

• Cardiovascular:

The treatment of heart blockages via coronary angioplasty and stenting.

• Peripheral Vascular:

Using the angioplasty and stenting to treat blockages in the arteries leading to the legs.

• Neurovascular:

Handling disorders of the nervous system, including stroke.

• Gastrointestinal:

They enable gastrointestinal procedures such as Endoscopic Retrograde Cholangiopancreatography, or ERCP.

• Urological:

They make the ureters accessible for different types of procedures.

Benefits of Hydrophilic Guidewires in Angioplasty:

Compared to conventional guidewires, hydrophilic guidewire has several important features that improve patient outcomes and procedure efficiency:

• Improved Trackability:

By reducing blood vessel friction, the lubricating coating makes it possible to go through even the most convoluted paths with ease. This lessens the possibility of becoming trapped or damaging the vessel.

• Decreased Trauma:

Because the lubricity reduces friction on the artery walls during catheterization, there is a lower chance of trauma or perforation. This might result in fewer problems and quicker patient recovery periods.

• Enhanced Procedural Success:

These guidewires reduce vascular trauma and enable seamless navigation, which raises the success rate of interventional operations.

• Enhanced Efficiency:

Shorter procedure durations may result in better trackability and a lower risk of complications. Less patient discomfort and maybe cheaper medical expenses result from this.

All things considered, hydrophilic guidewires are a great development in interventional medicine that has major advantages for patients as well as medical professionals.

What Considerations for Guidewires?

Although these guidewires have several benefits, there are a few things to consider to guarantee patient safety and best performance:

• Handling:

To preserve the hydrophilic coating’s integrity, proper handling methods are essential. Avoiding severe twisting or bending that might harm the coating and reduce lubrication is part of this.

• Catheter Compatibility:

Ensuring compatibility between the hydrophilic guidewire and other devices utilized in the process is crucial. This is known as catheter compatibility. Incompatibility may harm the guidewire and have an impact on performance.

• Catheter Selection:

For best navigation and outcomes, choose the right guidewire size and tip configuration for the particular surgery.

• Allergic Responses:

Although rare, allergic responses to the components in the hydrophilic coating may occur in certain people. It’s crucial to get advice in advance and be aware of any potential sensitivity.

Future of Hydrophilic Guidewires:

The following innovations are keeping this guidewire development moving forward:

• Enhanced Coatings:

Technological developments in coatings offer even more lubrication, which might further reduce friction and enhance navigation.

• Integrated Imaging:

To improve procedural precision, the next versions may incorporate imaging modalities for real-time viewing during navigation.

• Patient-Specific Customization:

Another possible frontier is customization according to the anatomy of the patient, which would enable customized guidewires that more effectively navigate distinct vascular channels.

These developments might lead to even more safety and efficiency in minimally invasive surgeries. Our website focuses on medical devices or minimally invasive procedures.

Hydrophilic Guidewire Safety Measures:

To ensure maximum safety when using these guidewires, adhere to these important guidelines:

• Inspection:

Before using the guidewire, check it often for damage indicators such as kinks or deterioration of the coating. Friction and danger may rise due to a compromised guidewire.

• Instructions:

For optimal handling, use, and compatibility with other devices, always follow the manufacturer’s instructions.

• Disposal:

To avoid contamination and environmental risks, dispose of discarded guidewires by medical waste standards.

Hydrophilic Guidewire Training & Education:

To maximize the application of these guidewires, healthcare personnel must have the appropriate training:

• Training Programs:

Specific programs instruct users on how to choose guidewires, handle them safely, and utilize them in conjunction with other interventional devices.

• Continuing Education:

To keep healthcare professionals up to speed in their industry, regular updates on hydrophilic guidewire technological improvements and best practices are provided.

• Training with Simulation:

Using simulation models enables controlled, hands-on practice and improvement of procedural skills using these guidewires.

Regulatory Considerations for Guidewires:

Hydrophilic guidewire development and application are subject to stringent regulations:

• Manufacturing Standards:

Medical device manufacturers must adhere to regulatory standards such as ISO .

• Approval Procedures:

To guarantee safety and effectiveness, new guidewire designs or revisions need to be approved by regulatory organizations like the FDA.

• Post-Market Surveillance:

It is essential to monitor hydrophilic guidewires following their introduction onto the market to spot and resolve any possible safety issues.

Conclusion:

Contact us to discuss your requirements of OEM Guide Wire. Our experienced sales team can help you identify the options that best suit your needs.