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Custom Cabling & Connectors
cables and connectors

U.S.-Based Cable Assembly Manufacturer, Engineered to Last

DEM Manufacturing is a 100% U.S.-based cable assembly manufacturer producing custom cables and connectors that perform in the toughest environments. Our ITAR registration (M47849), ISO 9001:2015 quality system, and IPC/WHMA-A-620 cable and harness certification mean that every assembly is built and documented to defense-grade standards within a compliant domestic chain of custody.

As a domestic wire harness manufacturer, DEM designs for military and law enforcement communication systems where clear, consistent signal cannot fail. Decades of building communications accessories make DEM a trusted source for electrical cable assemblies that survive vibration, submersion, and rough field handling.

  • Strain reliefs withstand pull forces up to 75 lbs
  • Tested for 5,000 90-degree bends
  • Multiple IP ratings up to IP9K, with waterproof options
  • Submersible operation up to 20 meters
cables and connectors

Our Testing Makes All the Difference

From military vehicles to aircraft and special forces personnel, every cable is engineered to endure. That’s because each product undergoes rigorous testing and inspection to meet the highest quality standards.

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What Sets Our Custom Cables and Connectors Apart?

Each solution is crafted to fit your project’s exact requirements.

Truly Custom

Virtually any connector type and configuration can be designed and produced. Each custom cable assembly is built to your project's exact requirements, and we design custom connectors to fit unique system setups.

Built for Rugged Environments

Our cables withstand intense physical use and are ideal for demanding applications, which is why agencies rely on DEM as a rugged communications partner.

Comprehensive Testing

Every cable and connector assembly undergoes rigorous QA/QC testing for maximum durability and reliable performance in the field.

Specialized Cabling for Communication Systems

Our cables support high-performance communication systems with strong, clear signals across platforms. They integrate with existing systems and handle audio and signal transmission without interruption or interference. As an assembly manufacturer with full in-house control, DEM configures each electrical cable by length, color, and coiling, with connectors at specific IP ratings and PCBAs integrated directly into cable splices or custom connector housings.

From a custom wire harness for a tactical platform to sealed, submersible assemblies, DEM supports nearly every radio used by federal and law enforcement agencies. Our 10-pin connector cable solutions are built for harsh environments, compatible with OEM radio platforms, and configurable to meet MIL-STD specifications.

Our Cabling Solutions Can be Tailored To:

  • Configuration
  • Color
  • Length
  • Coiled cables
  • Connectors with specific IP ratings
  • Integrate PCBAs into cable splices or custom connector housings

We Design Cables For:

  • Up to IP9K
  • Nearly every radio used by federal and law enforcement agencies
  • Up to 20-meter submersible operation

Our Capabilities

Printed Circuit Board Assemblies (PCBAs)

Printed Circuit Board Assemblies (PCBAs)

Analog & Digital Communication and push-to-talk devices

Analog & Digital Communication

Tooling Design & Fabrication for electronic device manufacturing

Tooling Design & Fabrication

3D Printing & Prototyping

3D Printing & Prototyping

Injection Molded Components

Injection Molded Components

Medical Device component manufacturing

Medical Devices

One Accountable Partner for Cables and Connectors

Whether you are adapting to a legacy system or deploying something new, our team designs and delivers custom wire and cable assemblies to your exact requirements, no matter how demanding the application. As a single manufacturer for your cabling and connectors, DEM keeps design, build, and testing under one domestic roof. Talk to an expert about solving your cabling challenge.
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FAQs

1. Can you support unique use cases with custom cables and connectors?

Yes. DEM specializes in custom cables and connectors designed to meet non-standard requirements, including integration with proprietary devices, military-grade systems, and legacy tech, often where off-the-shelf solutions fall short.

2. What should I consider when choosing cable connector manufacturers?

When evaluating cable connector manufacturers, consider their ability to deliver durability, speed, and configuration flexibility. DEM stands out by offering U.S.-based manufacturing, flexible order volumes, and design-for-manufacturability expertise, all under one roof.

3. Does DEM offer rugged 10 pin connector cable assemblies for defense applications?

Absolutely. Our 10 pin connector cable solutions are built for harsh environments, compatible with OEM radio platforms, and configurable to meet MIL-STD specifications and specific equipment needs.

4. As a cable assembly manufacturer, which radio platforms are your cables compatible with?

As a cable assembly manufacturer, we build cables compatible with nearly every radio used by federal and law enforcement agencies, including platforms from Harris, Thales, Silvus, and Persistent Systems, with custom configurations available.

5. How deep can your electrical cable assemblies be submerged without failing?

Our electrical cable assemblies support submersible operation up to 20 meters, with IP ratings up to IP9K and strain reliefs rated to 75 lbs, so they hold up in wet and demanding field conditions.

6. Are DEM's cables and connectors ITAR compliant?

Yes. DEM is ITAR registered (M47849), and our cable and harness work is certified to IPC/WHMA-A-620, built entirely in the USA to defense-grade standards inside a compliant, domestic chain of custody.

7. Can DEM integrate a circuit board into a cable assembly?

Yes. We integrate PCBAs directly into cable splices or custom connector housings, and configure each assembly by length, color, coiling, and connector IP rating to match your exact system requirements.

8. Does DEM build cables for legacy radio systems?

Yes. Our 10-pin connector cable solutions are configurable to MIL-STD specifications and compatible with both current and legacy OEM radio platforms, so you can adapt existing systems or deploy new ones.

9. How durable are your cables in the field?

DEM cables withstand pull forces up to 75 lbs and pass testing for 5,000 90-degree bends, and every assembly undergoes rigorous QA/QC testing for maximum durability before it ships.