RF Cable
Assemblies.

A European thermal imaging OEM experienced a critical production halt due to high impedance defects in a micro-coaxial cable assembly used for a beta production series.

Challenge

1,296 out of 2,000 units of AWG#40 CABLINE-VS 1:1 100mm micro-coax assemblies failed due to high impedance, leading to order cancellation, a demand for refunds, and a major trust deficit.

Solution

Halted production immediately and conducted joint technical analysis with the customer's engineering team to identify the root cause — a specification definition and testing-method mismatch between the customer's RF lab and our incoming impedance verification. Updated test specifications, provided new test reports, manufactured replacement samples, and processed a full replacement order for the defective units.

Result

Successfully resolved the quality complaint, secured a replacement order for all 1,296 defective units, and maintained the long-term partnership despite the severe initial defect rate. The corrected impedance verification procedure has been applied to every micro-coax assembly since.

A North American 3D vision and industrial measurement OEM required strict intellectual property protection before engaging with a contract manufacturer for custom cable assemblies.

Challenge

The customer's procurement process involved a multi-tier approval system and a strict NDA requirement, causing a 3-month vetting period during which no technical specifications could be exchanged, delaying the quoting process and the customer's NPI gate.

Solution

Promptly executed the NDA, provided comprehensive company background, audit history, and capability data to pass HQ and Supply Chain Manager vetting. Once specs were released, rapidly generated a detailed quote with crimp tooling references, ferrule die sizes, and the full QA test plan.

Result

Passed the stringent vendor qualification process, secured the signed NDA, and received the formal inquiry with detailed drawings. Quoted a 4-week lead time for the custom assembly and won the program for ongoing production builds.