OMN E T IC S CA B L E H A R NESS SOLUT IONS

Omnetics specializes in miniature connectors and small wire gauge

interconnects and is well suited to meet the cable harness needs of our
customers, with IPC-610 and IPC-620 trained workers on-site.

HASSLE-FREE CUSTOMIZATION RELIABILITY

A wide range of cable Omnetics’ cable Omnetics’ techniques
and wire configurations assemblies are 100% enhance ruggedness
 OUR EXPERTISE

Omnetics specializes in application-specific connector to cable systems. Our expert

designers have experience designing harnesses for complex and harsh environment
applications. Omnetics designers have the necessary experience needed to meet the
Quality and Performance specifications required by the US Military, NASA and ESA.

Our experience with all types of connectors Cable and Harness shielding are critical to the
and cables in a wide array of markets means function of the connected device. Typical
Omnetics will satisfy your cable harness shielding methods are braided shield, spiral
needs. shield and a foil shield with or without a drain
wire. There can also be combinations of the
Omnetics works directly with you to methods, for example, it is common to braid
determine the proper material for your over a foil shield with a drain wire. Each
application. Materials such as FEP, PFA and shielding method has its place depending on
PTFEs suit aerospace applications. PVCs, the desired EMI performance.
Urethanes, and Silicone jackets are standard
selections. We also have experience with a One specialty at Omnetics is our coax and
wide range of Customer Supplied materials. higher speed digital cable offered to match
key requirements, such as impedance,
When cable flexibility is important, high differential signal management and
performance copper alloys or copper wavelength of the signals. A mixed signal
conductors with 19 or more strands are used. cable offers a variety of power, coax and or
higher-speed in a compact custom connector.
High strength copper alloys will increase the These designs save space and weight. Our
wires break strength. Another option is to use specialists in hybrid cable and connectors are
a Kevlar or Nomex strength member to ready to discuss these great options with you.
increase the break strength of the Harness.
Flexibility, tensile strength, patient
To finish off the bundle, Lacing tape and wear-ability, biocompatibility, flame retardant,
heatshrink tubes are available; these help flex life, sterilization, shielding and signal
improve the harness flexibility and ease of integrity, lightweight and more.
routing.
 O U R C A PA B I L I T I E S

We design and manufacture a wide range of custom cable

solutions to support all of our various product lines, while
allowing your team to guide the design.

To minimize the design cycle time, Omnetics utilizes

engineer-to-engineer communications. Omnetics will be
available to assist your team from the developmental stages, to
prototyping all the way through production. Omnetics’ Design
Engineering Team uses SolidWorks.

Omnetics does not typically charge for our engineering

services which allows our customers to explore solutions to
• Signal integrity
their interconnect challenges without having to generate POs
• EMI
or go through lengthy approval processes.

We are able to offer step files, printed prototypes and drawings

prior to finalizing the design. This minimizes customer risk and
results in successful implementation for prototype and
production assemblies.

Omnetics Connector Corporation follows IPC/WHMA-A-620 for

all cable assembly, test and inspection practices.

• Immersion
• Salt spray or exposure
Cu sto m Ca b le Asse mb ly O pti on s

• Wire-to-wire jumpers • Shielded Cable Assemblies

• Complex multi-branch • RF/Coaxial Cable Assemblies
. assemblies
• Medical Device Cable
• Mixed Signals and Power . Assemblies
. and/or Coax o ISO 7 cleanroom
• Data & Video Cables o Autoclavable
o HDMI, CAT-6, USB 3.0, . • Military Connectors
. Cameralink
o MIL-DTL-32139 / -83513 /
• Custom Overmolded Cables . -24308 / -38999
o Custom Logos and branding • Space Wire
o Strain relief and unique o Cable per ESCC 3902/003
. geometries
o Assemblies per
o Waterproof sealing (i.e. IP68)
. ECSS-E-ST-50-12C Rev. 1
• Flat Cable/Ribbon Cables
o Type A and AL
• Flex Circuit Assemblies

Cab l e As se mb ly P roc e ss i n g Capabi l i ti e s

• Wire to wire connectors • Potting/encapsulation

• Wire to board connectors • Automated and manual crimp
• High speed performance . stations available
. simulations • Precise cut lengths
• Single and multi-row • Machine and slip-on Braiding
. connectors . options available
• Winding ferrite rings or • Injection Molding
. chokes • Tie and Lacing
• Ring terminals • Custom Wrapped Tapes and
• Ferrules . Foils
• Splicing and butt connections • Overmolded Strain Reliefs
• Standard and gold plating • Soldering
. options • 3D Printing
• IPC-620 compliant crimping • IPC-620-Space Addendum
. connections

Test i n g

• Full electrical Test – IR. • IP Testing

. DWV, Continuity
• Group A
• Pull Testing
• Group B
• Crimp Testing
• Qualification Testing
• Temperature Cycling
 CABLE HARNESS CHECK LIST

In many cases, connector and cable designers must ensure their interconnection
equipment is designed to survive and perform well beyond the standard specifications
in truly extreme environments.

By using a checklist to compare potential hazards, one can define what connector materials to
use. This list helps a designer determine what method of latching, sealing or insulating will be
required. Each portion of the connector and cable should be reviewed against the list. Frequent
reference to the harsh-environmental conditions will keep design on track and assure better
performance in the end. Sitting down with our designer and going through the demands help
define the connectors and cables that fit best.

Mechanical design related elements

01 • Shock • Water Seal – depth and length
• Vibration • Connector - open or closed
• Physical abuse • Corrosion resistance
• Locking mechanism

Electrical performance
02
• Connections • Signal integrity
• Number of mates and • EMI
. de-mates for life
• Electrical breakdown resistance

Environmental
03 • Temperature • Dust
• UV or infra-red exposure • Outgassing of materials
• Petroleum exposure
• Other chemicals

Cable
04 • Bend radius • Immersion
• Stress in length
• Repeated motion (ie. robots)
• Crush under pressure
CORE STRENGTHS OUR EXPERIENCE

Most common wire is focused on high Omnetics cable harness solution design
strength, highly flexible, small diameter and manufacturing experiences have
wire: included:

• 26 AWG Teflon insulated multi-strand • Cables from micro to nano-sized

. cable or open wiring . connectors
• 30 AWG Teflon insulated multi-strand • Hybrid signal and power connectors
. cable or open wiring • Mixed signal power and signal to
• 32 AWG Teflon insulated multi-strand . Omnetics mixed signal circular
. cable or open wiring . connectors
• Purchased or customer supplied wiring • Wiring and cable harness from modified
• Thermo-couple wiring . connectors to standard connectors
• Polyimide Flex cable • Wire harness with mixed-signal wiring
. for power and signal to other D-shaped
• Fabric braided cable for high flex
. connectors
• Flat ribbon wire
• Circular 38999 connectors wired to
• Flex circuit interconnections
. Omnetics micro/nano connectors
• Board to circuit and board to board
• Cochlear interconnect harness to nano
• Looping cable for stacking board . connectors
. interconnections

sales@omnetics.com
+1 763-572-0656