Mid-Atlantic Rubber Inc

Cable Assembly Services

Request a quote

Cable Assembly Services

Our Cable Assembly Capabilities

MAR’s cable assembly department handles the full scope of custom cable work, from initial design assistance through finished, tested assemblies:

Design & Engineering

  • Custom cable design from scratch or build-to-print from your existing drawings and specifications.
  • Connector selection support from our qualified supplier network across MIL-SPEC, medical, and commercial grades.

Assembly & Integration

  • Complete harness assembly with connectors, terminals, splices, and breakouts built to your configuration.
  • Multi-conductor, coaxial, fiber optic, and hybrid cable configurations. Single assemblies or full harness sets.

Overmolding & Sealing

  • In-house injection molding for overmolded strain reliefs, connector boots, and environmental seals rated to IP67 and beyond.
  • Liquid Silicone Rubber (LSR) overmolding for biocompatible, high-temperature, and chemically resistant applications.

This combination of cable assembly and overmolding capability in one facility is what sets MAR apart. Most cable houses send overmolding work to a separate vendor, which adds lead time, cost, and a potential point of failure. At MAR, the cable gets built and overmolded under the same roof, by the same team, with the same quality standards applied from start to finish.

Cable Assembly Services

Why Manufacturers Choose MAR for Cable Assemblies

In-House Overmolding

Most cable assembly shops outsource overmolding. MAR does it on site with our injection molding department, which means tighter integration, faster turnaround, and fewer vendors to manage.

Quality Connectors

We source connectors from established, qualified suppliers across MIL-SPEC, medical, and commercial product lines. No generic substitutes. No corner-cutting.

Design Assistance

Don’t have a finished cable design? Our team can help you spec the right conductor types, shielding, connectors, and sealing approach for your application. We’ll work from a concept or a napkin sketch.

Build-to-Print

Already have a drawing or spec? Send it over. We build to your exact documentation, including MIL-SPEC and IPC workmanship standards where required.

Testing & Verification

Every cable assembly is electrically tested before it ships. Continuity, hi-pot, insulation resistance, and functional tests are performed based on your requirements.

Multi-Capability Shop

Need machined enclosures, water jet-cut gaskets, or laser-cut brackets to go with your cable assemblies? We produce those in the same facility. Your entire order ships together.

Cable Assembly Services

What We Build

Our cable assembly department produces a wide range of cable types and configurations to meet the needs of demanding applications:

Power cables

Single and multi-conductor power cables with rated connectors for equipment, vehicles, and field-deployed systems.

Signal and data cables

Low-voltage signal cables, shielded data cables, and twisted pair configurations for sensors, communications, and control systems.

Coaxial assemblies

RF and coaxial cable assemblies for communications, radar, and test equipment with precision connectors.

Fiber optic assemblies

Single-mode and multi-mode fiber assemblies with terminated connectors for high-bandwidth data transmission.

Hybrid cables:

Combined power, signal, and data in a single assembly with breakouts and multi-pin connectors.

Wire harnesses

Multi-branch harnesses with labeled leads, lacing, and protective sleeving for complex system installations.

Overmolded assemblies

Cables with molded-on strain reliefs, connector housings, and environmental seals for ruggedized, sealed connections.

Custom Gaskets & Foam Products

Connectors & Components

We work with a broad range of connector families and cable types sourced from qualified industry suppliers:

Connector Types

  • MIL-DTL-38999 (circular, high-density)
  • MIL-DTL-26482 (miniature circular)
  • D-Sub connectors (standard & high-density)
  • Micro-D / Nano-D connectors
  • Circular plastic connectors (Molex, TE)
  • USB, Ethernet, and data connectors
  • Custom and application-specific connectors

Cable & Wire Types

  • Multi-conductor shielded cable
  • Coaxial (RG-series and specialty)
  • Twisted pair (shielded & unshielded)
  • Fiber optic (single-mode & multi-mode)
  • Flat ribbon cable
  • Silicone and PTFE jacketed wire
  • High-temp and radiation-resistant cable

If your application requires a specific connector or cable type not listed here, reach out. Our supplier network is broad, and we regularly source specialty components for unique requirements.

Custom Gaskets & Foam Products

Industries We Serve

Our cable assembly services support manufacturers and integrators in industries where reliability, durability, and electrical performance are critical:

  • Military & Defense
  • Aerospace & Aviation
  • Medical Devices & Diagnostics
  • Industrial Controls & Automation
  • Communications & Telecommunications
  • Test & Measurement Equipment
  • Robotics & Unmanned Systems
  • Energy & Power Systems

Case Study

Ruggedized Cable Assemblies for a Portable Military Communications System

Client Name

Blackridge Defense Solutions

Industry

Military / Defense

Location

Quantico, VA

Cable Assembly Services

The Challenge

Blackridge Defense Solutions builds portable tactical communications kits used by field units across multiple branches of the U.S. military. Each kit contains a radio module, an antenna interface unit, a power distribution box, and a ruggedized display. These components are connected by a set of five custom cable assemblies that carry power, RF signal, and digital data between the modules.

Blackridge had been sourcing their cable assemblies from a contract manufacturer in the Midwest. The cables met basic electrical specs, but Blackridge’s field teams were reporting failures at an unacceptable rate. The most common issues were connector pull-outs at the strain relief, moisture intrusion through the connector interface, and cracked cable jackets after repeated deployment and stowage cycles. Environmental testing confirmed that the assemblies were not holding up to the temperature extremes, vibration, and rough handling that field conditions demanded.

Blackridge’s program manager needed a cable assembly partner who could deliver mil-grade build quality with proper environmental sealing, and who understood the abuse these cables would take in the field.

Cable Assembly Services

The MAR Solution

Blackridge contacted MAR after learning about our combined cable assembly and injection molding capabilities. After reviewing the existing cable designs and failure reports, our team identified three specific areas where we could improve the assemblies:

Here’s why silicone sponge was the right call:

Overmolded strain reliefs

The original cables used heat shrink tubing as strain reliefs, which offered minimal pull-out resistance. MAR designed custom LSR overmolded strain reliefs that bonded directly to the cable jacket and connector body, creating a monolithic transition that distributed stress across a wider area. Pull-out strength increased by over 300%.

Integrated environmental seals

Instead of relying on O-rings and adhesive seals at the connector interface, we overmolded a silicone sealing boot directly onto each connector. This provided consistent IP68-rated sealing that survived repeated mate/de-mate cycles without degradation.

Upgraded cable jacket

We replaced the standard PVC jacket with a TPU (thermoplastic polyurethane) jacket rated for -40°F to 250°F. TPU is significantly more resistant to abrasion, flexing, and UV exposure than PVC, which directly addressed the cracked jacket failures.

We also upgraded the connectors to MIL-DTL-38999 Series III on the high-density data connections and sourced all components through our qualified mil-spec supplier network. Every assembly was built to IPC/WHMA-A-620 Class 3 workmanship standards and 100% electrically tested before shipping.

First article samples were delivered within three weeks. Blackridge ran them through a full qualification cycle including temperature shock, vibration, salt spray, and 500 mate/de-mate cycles. All five assemblies passed on the first submission.

Cable Assembly Services

The Results

After transitioning to MAR-built cable assemblies, Blackridge tracked field performance over the first 12 months of deployment:

92% Reduction

in field cable assembly failures

IP68 Sealed

across all five assembly types

300%+ Increase

in connector pull-out strength

The improved reliability had a direct impact on Blackridge’s bottom line. Warranty replacement costs on cable assemblies dropped by over $45,000 in the first year. Field units reported fewer communication outages caused by cable failures, and Blackridge’s reputation with their military customers strengthened as a result.

Blackridge has since expanded their work with MAR to include two additional cable assembly programs for new product variants, plus a set of water jet-cut gaskets for the communications kit enclosures. Having one supplier handle both the cables and the sealing components simplified their supply chain and ensured dimensional compatibility across the entire kit.

“Our previous cables were failing in the field because they weren’t built for the real conditions our troops face. MAR understood the problem immediately and delivered assemblies that are tougher, better sealed, and built to a standard our military customers expect. The overmolded design is a massive improvement over heat shrink, and having the cable and gasket work under one roof made the whole program easier to manage.”

Lt. Col. (Ret.) Marcus Webb

Program Manager, Blackridge Defense Solutions

our process

Our Process: From Spec to Shipped Assemblies

Working with MAR is straightforward. Here’s how a typical custom gasket project moves from concept to delivery:

Share Your Requirements

Send us your cable assembly drawing, specification, or even a description of the application. Include connector types, pin assignments, cable lengths, environmental requirements, and quantities. If you don’t have a finished design, our team can help you develop one.

Design Review & Quoting

We review the requirements, confirm connector and cable sourcing, and provide a detailed quote. If overmolding or special testing is needed, we’ll include that in the scope.

Build & Overmold

We assemble the cables, terminate connectors, and overmold strain reliefs and sealing features as required. All work follows IPC/WHMA-A-620 workmanship standards.

Test & Deliver

Every assembly is electrically tested and visually inspected. Continuity, hi-pot, and functional tests are performed per your specification. Assemblies ship labeled, bagged, and ready for installation.

Need Custom Cable Assemblies?

Send us your spec or describe your application. We’ll help you design and build the right cable for the job.

request a quote