--- title: Understanding Your Custom Cable Assembly Testing Requirements description: Understand custom cable assembly testing requirements, including continuity, hipot, mechanical, EMC, and environmental tests to improve reliability. image: https://blog.epectec.com/hubfs/blog/cable-assembly-flex-test.jpg --- [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) [![Epec Engineered Technologies](https://www.epectec.com/images/logo.png "Epec Engineered Technologies")](https://www.epectec.com/) - [Articles](https://www.epectec.com/articles/) - [Blog](https://blog.epectec.com/) - [Webinars](https://www.epectec.com/webinar/) - [Videos](https://www.epectec.com/videos/) - [Case Studies](https://www.epectec.com/case-studies/) - [News & Events](https://www.epectec.com/news/) - [Customer Portal](https://system.netsuite.com/c.406760/site/NSlogin.html) - [About](https://www.epectec.com/about/overview/) - Back - [Company Overview](https://www.epectec.com/about/overview/) - 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[Register](https://secure.epecpcb.com/epec/index2.jsp) [![](https://www.epectec.com/images/InstantPCBQuote-logo.png)](https://www.epectec.com/instantpcbquote/) [Login](https://secure.epecpcb.com/epec/) [Register](https://secure.epecpcb.com/epec/index2.jsp) Register to Quote and Order Your PCBs Fast, Easy & Online, 24/7 - [Home](https://www.epectec.com/) - [Blog](https://blog.epectec.com/) - Understanding Your Custom Cable Assembly Testing Requirements Share This Page: [LinkedIn](https://blog.epectec.com/#linkedin) [X](https://blog.epectec.com/#x) [Facebook](https://blog.epectec.com/#facebook) [Email](https://blog.epectec.com/#email) # Understanding Your Custom Cable Assembly Testing Requirements [![Steven Goodman](https://blog.epectec.com/hubfs/Blog-Authors/steve-goodman.jpg "Steven Goodman")](https://blog.epectec.com/author/steven-j-goodman) Written by [Steven Goodman](https://blog.epectec.com/author/steven-j-goodman) Posted on November 20, 2019 at 9:57 AM ![Steven Goodman](https://blog.epectec.com/hubfs/Blog-Authors/steve-goodman.jpg "Steven Goodman") - [Tweet](https://twitter.com/share) [Custom cable assemblies](https://www.epectec.com/cable-assemblies/) are used across a wide range of applications to transmit power, data, and high-fidelity signals. In many cases, they support mission-critical or life-saving equipment where reliability is essential. To perform successfully, a cable assembly must maintain electrical integrity, withstand mechanical stress, and resist the environmental conditions it will encounter throughout its service life. Testing requirements are often established during product development and qualification activities to verify that the design satisfies application-specific performance requirements. Once qualification testing is complete and manufacturing begins, additional in-process or final inspection testing may be required to ensure production assemblies continue to meet those requirements. **Before launching a custom cable assembly program, it is important to define:** - Which tests are required - When testing will occur - What additional connectors and test equipment are needed - Whether testing is performed in-process or during final inspection - Whether testing applies to 100% of assemblies or an Acceptance Quality Limit (AQL) sample - The pass/fail criteria for each test Establishing these requirements early can help reduce redesign risk, control manufacturing costs, and improve time to market. [![Check Out Our Tips on Cable Assembly Design!](https://no-cache.hubspot.com/cta/default/707152/2b2d2d36-33a4-46c5-b3f9-308eff53a644.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/2b2d2d36-33a4-46c5-b3f9-308eff53a644) ## Testing Requirements Depend on the Application [Electrical continuity testing](https://blog.epectec.com/custom-cable-assembly-testing-is-continuity-testing-enough) is considered standard for most custom cable assemblies because the primary function of a cable assembly is to create an electrical connection between devices. Epec performs 100% electrical continuity testing on all our cables. Some applications require significantly more testing. [Medical devices](https://www.epectec.com/cable-assemblies/medical-device-cables.html), [mil-aero](https://www.epectec.com/cable-assemblies/military-wire-harnesses.html), and other high-reliability applications often require additional electrical, mechanical, and environmental validation before assemblies can be approved for use. When testing requirements are unclear, the end customer should define the applicable standards, acceptance criteria, and performance expectations. ## When Cable Assembly Testing Is Performed Most testing takes place during final inspection [after manufacturing is complete](https://blog.epectec.com/cable-assemblies-testing-after-manufacturing). These tests verify that the cable assembly was built correctly and performs as intended. Certain tests may also be performed during manufacturing to verify specific process steps. For example, performing required hipot testing before heat-shrink tubing is fully recovered can simplify troubleshooting and repair activities, particularly for complex cable harnesses. Testing requirements influence both manufacturing cost and production schedule. Specialized test equipment, custom fixtures, and dedicated test apparatus may be necessary. Some test methods are destructive and can damage the assembly being evaluated, making early planning important when defining a test strategy. ## Electrical Testing Requirements Electrical testing verifies that the cable assembly has been assembled correctly and can safely perform its intended electrical function. **Three commonly specified tests are:** - Electrical continuity testing - High potential/high voltage (hipot) testing - Milliohm testing Together, these tests help verify proper wiring, identify open circuits, detect short circuits, and uncover intermittent electrical connections that could affect reliability. For some cable assemblies, mating connectors must be incorporated into the test apparatus. This can become an important schedule consideration when specialized connectors have long procurement lead times. ## Electrical Continuity Test A continuity test verifies that wires and connectors are assembled correctly and that electrical current can flow through the cable assembly as intended. The test measures circuit resistance and confirms that an electrical path exists between designated test points. Open circuits resulting from damaged conductors or broken wires can be identified during testing. Elevated resistance values may indicate poor connections that could eventually fail in service. Continuity testing is typically performed using a multimeter configured to measure either resistance (Ω) or continuity. The instrument applies a small voltage between test points and measures the resulting resistance. Modern automated test equipment can evaluate all conductors within a multiconductor cable simultaneously. Because each cable design has a unique pinout configuration, these automated systems typically require customized fixtures and test programming. ## High Potential (Hipot) Testing A high potential test, commonly referred to as a hipot test, evaluates the dielectric strength of a cable assembly's insulation system. The test is intended to identify insulation defects, contamination, gaps, current leakage, and internal short circuits. During testing, a high voltage, sometimes exceeding 10 kV, is applied between conductors to place significant electrical stress on the insulation and soldered connections. When the cable assembly successfully withstands the specified test voltage for the required duration, the results indicate that the insulation system can tolerate normal operating voltages as intended. Multiconductor cable assemblies present additional testing challenges. Adjacent conductors typically require individual evaluation. While this process is straightforward for assemblies with only a few conductors, cable assemblies exceeding 20 conductors may require hundreds or even thousands of individual conductor-to-conductor measurements to fully evaluate insulation performance. Automated HIPOT systems are available for these applications, although the equipment can represent a significant investment. ## Milliohm Testing A milliohm test measures extremely low-resistance electrical connections within a cable assembly. The purpose of the test is to verify connection quality and ensure that resistance values remain within an established acceptance range. Ground circuits are a common application because these circuits often require exceptionally low resistance values that cannot be measured accurately using standard multimeters. Milliohm testing uses a four-terminal measurement method. Current is applied through one set of terminals while voltage is measured through a separate set. This configuration improves measurement accuracy when evaluating very low resistance values. One example of an electrical bonding requirement is a maximum resistance of 2.5 milliohms between two ground points. Assemblies exceeding the specified limit are rejected and require further evaluation. ## EMI and EMC Testing Requirements Electromagnetic interference (EMI) and electromagnetic compatibility (EMC) testing evaluate whether equipment generates excessive electrical noise and whether it continues operating when exposed to electromagnetic disturbances. Cable assemblies affect both because they can carry interference between devices, radiate electrical noise, or couple external interference into connected electronics. Requirements depend on the application. Common references include MIL-STD-461 for military equipment, RTCA/DO-160 for airborne equipment, and IEC 60601-1-2 for medical electrical equipment. CISPR 11 and CISPR 32 address emissions from equipment within their respective scopes, including industrial, scientific, medical, and multimedia products. These emissions standards do not, by themselves, cover every immunity requirement. The applicable standard, revision, test levels, and acceptance criteria should be established during development. ## Testing the Cable Within the Operating System System-level EMC testing generally requires the cable assembly to be connected to operating equipment, representative loads, and supporting devices. Although a cable can be evaluated separately for characteristics such as shielding effectiveness, a passive cable alone cannot demonstrate how the complete system emits interference or responds to disturbances. Cable length, routing, connector construction, shield termination, and chassis grounding can affect results. The test configuration should follow the applicable standard and represent the intended installation, with operating modes selected to exercise relevant power, signal, and communications functions. Performance must be monitored during testing to identify problems such as communication errors, resets, or interrupted operation. ## Common EMI and EMC Evaluations Depending on the equipment and applicable requirements, testing may include: - **Radiated emissions:** Measures electromagnetic energy radiated by the operating equipment and its cables. - **Conducted emissions:** Measures unwanted electrical noise traveling along power leads or other specified cable connections. - **Radiated immunity or susceptibility:** Evaluates operation during exposure to electromagnetic fields. - **Conducted immunity or susceptibility:** Introduces disturbances onto specified cables or power leads to evaluate the equipment’s response. - **Electrostatic discharge (ESD):** Evaluates resistance to static discharges at specified accessible surfaces and test points. - **Voltage spikes, surges, and electrical fast transients:** Evaluates responses to specified transient waveforms associated with switching events or other electrical disturbances. - **Additional application-specific tests:** May include magnetic-field immunity, voltage dips and interruptions, induced-signal susceptibility, or lightning-induced transients on aircraft wiring. These tests are not interchangeable, and not every test applies to every assembly or system. The test plan must identify the required methods, affected ports, exposure levels, and allowable performance changes. ## Plan Laboratory Testing Early Radiated testing may require an anechoic or semi-anechoic chamber, while other evaluations use specialized bench equipment or alternative test facilities permitted by the standard. Chamber availability, specialized equipment, fixtures, and supporting hardware can introduce substantial lead times. Confirm laboratory capabilities and scheduling early, and allow time for troubleshooting, design changes, and repeat testing. Preliminary EMC checks before formal qualification can help identify problems while cable construction, shielding, and grounding details are still practical to revise. ## Mechanical Testing Requirements Mechanical testing evaluates a cable assembly's ability to withstand physical stresses encountered during installation and operation. **Characteristics commonly evaluated include:** - Tensile strength - Elongation - Impact resistance - Crush resistance - Fatigue resistance Two widely used mechanical tests are pull testing and flex/bend testing. ## Pull Testing A pull test measures the strength of wires, connectors, terminals, and crimped connections. All pull tests are performed to the terminal or connector manufacturers assembly instructions. For some projects, our customers will specify additional pull testing requirements to supplement the screening process. Testing is performed by applying a specified load at a defined rate while monitoring the cable assembly's response. Test conditions vary depending on the conductors, terminals, and connector systems used. Some applications require verification that a cable assembly can withstand a specified tensile load without visible damage. One example provided in customer requirements is demonstrating resistance to 40 pounds of tensile force without observable damage following testing. ![A pull test determines the strength of the wire, connectors, and crimp joints](https://blog.epectec.com/hs-fs/hubfs/blog/cable-assembly-pull-test.jpg?width=800&name=cable-assembly-pull-test.jpg) *A flex/bend test is used to assess the cable's durability to bending fatigue.* ## Flex and Bend Testing Many cable assemblies experience repeated routing, bending, twisting, and movement throughout their service life. These motions should not interrupt signal transmission, power delivery, or mechanical integrity. Flex and bend testing evaluates resistance to bending fatigue and helps determine whether the cable assembly can withstand expected operating conditions. Testing may be performed using dedicated bend and flex equipment where one end of the cable remains fixed while the opposite end is subjected to controlled movement. Common approaches include: - Repeated bending to a 90-degree angle - Rolling bend testing using a swing-arm mechanism - Cyclic flexing through an 180-degree arc To obtain meaningful results, the minimum bend radius and required number of cycles should be defined before testing begins. ![A flex/bend test is used to assess the cable's durability to bending fatigue](https://blog.epectec.com/hs-fs/hubfs/blog/cable-assembly-flex-test.jpg?width=800&name=cable-assembly-flex-test.jpg) *A pull test determines the strength of the wire, connectors, and crimp joints.* ## Environmental Testing Requirements Cable assemblies are frequently exposed to demanding operating environments. Conditions such as temperature extremes, [humidity](https://www.epectec.com/cable-assemblies/high-moisture-humidity-exposure.html), condensation, submersion, saltwater exposure, and salt fog can accelerate corrosion, degrade insulation systems, and reduce service life. Many environmental testing requirements originate from customer specifications or compliance requirements. **Common environmental evaluations include:** - High-temperature storage - Low-temperature storage - Thermal shock - Thermal cycling - Waterproofness testing - Vibration testing - Humidity testing - Chemical and fluid exposure testing - Salt spray testing - Fungus exposure testing Some manufacturers can perform these evaluations internally, while specialized testing may require third-party laboratories. Because environmental testing often involves dedicated chambers and specialized equipment, it can significantly affect project cost and schedule. ## Understanding IP66 and IP67 Water Ingress Protection Ratings Cable assembly specifications frequently reference International Protection (IP) ratings defined by the International Electrotechnical Commission (IEC). **An IP code contains two digits:** - The first digit specifies protection against solid particles such as dust. - The second digit specifies protection against liquids such as water. ### IP66 An IP66-rated cable assembly is completely protected against dust ingress and resistant to water intrusion from high-powered water jets directed from any angle. ### IP67 An IP67-rated cable assembly is completely protected against dust ingress and resistant to water ingress during temporary submersion. Manufacturers often design cable assemblies and production processes to meet IP performance requirements. Formal certification is typically issued by an appropriately recognized third-party laboratory. ### Fungus Resistance Testing Fungal growth can occur when cable assemblies are exposed to warm,[humid environments](https://www.epectec.com/cable-assemblies/high-moisture-humidity-exposure.html) for extended periods. Marine applications can be particularly susceptible because moisture and darkness may promote biological growth. [Fungal contamination](https://www.epectec.com/cable-assemblies/high-moisture-humidity-exposure.html) can contribute to corrosion, premature aging, and degradation of cable jackets, connectors, and conductors. One commonly referenced evaluation method is MIL-STD-810 fungus testing. In this process, material coupons are exposed to fungal spores and placed into a controlled warm, humid environment designed to encourage growth. The coupons are then monitored to evaluate fungal growth and growth rate. ## Summary The most effective cable assembly testing strategy is determined by the application, operating environment, customer requirements, and reliability objectives. Continuity testing may be sufficient for some assemblies, while others require extensive electrical, mechanical, and environmental validation. Defining test methods, acceptance criteria, inspection quantities, and timing before production begins helps prevent costly surprises and supports a smoother transition from development into manufacturing. --- ## Key Takeaways - **Testing Is Application-Driven:** Basic continuity testing is standard, but medical, military, or mission-critical applications often require more rigorous electrical, mechanical, and environmental tests. - **Multiple Test Types Ensure Reliability:** Common tests include electrical continuity, hipot (dielectric strength), milliohm (low-resistance bonding), mechanical pull and flex/bend tests, and environmental evaluations like thermal shock, vibration, salt spray, and IP66/IP67 ingress protection. - **Testing Impacts Cost and Lead Time:** More tests, especially those needing specialized equipment or third-party labs (e.g., IP certification or fungal testing), can significantly increase manufacturing cost and production time. - **IP Ratings Provide Environmental Assurance:** IP66 ensures protection from high-powered water jets, while IP67 offers dustproofing and short-term submersion resistance, making these key ratings for outdoor and rugged-use assemblies. - **Collaboration Improves Results:** Engaging manufacturers early to define test types, pass/fail criteria, and frequency (e.g., 100% inspection vs. AQL sampling) can reduce redesign risks and help achieve faster time-to-market. - [Tweet](https://twitter.com/share) Topics: [Cable Assemblies](https://blog.epectec.com/topic/cable-assemblies) --- [Next](https://blog.epectec.com/managing-the-development-of-your-overmolded-cable-q-and-a) | [All posts](https://blog.epectec.com/all) | [Previous](https://blog.epectec.com/five-tips-when-substituting-cable-assembly-connectors) [![New call-to-action](https://no-cache.hubspot.com/cta/default/707152/aa920eaf-6806-4ac9-a6e3-1ac5ce9edf5e.png)](https://cta-redirect.hubspot.com/cta/redirect/707152/aa920eaf-6806-4ac9-a6e3-1ac5ce9edf5e) ## Leave a Comment --- ## Related Posts --- ### Recent Posts --- ### Posts by Topic - [Printed Circuit Boards (162)](https://blog.epectec.com/topic/printed-circuit-boards) - [Product Design (138)](https://blog.epectec.com/topic/product-design) - [Battery Packs (122)](https://blog.epectec.com/topic/battery-packs) - [Cable Assemblies (102)](https://blog.epectec.com/topic/cable-assemblies) - [Flex & Rigid-Flex PCB's (96)](https://blog.epectec.com/topic/flex-rigid-flex-pcbs) - [Electronics Industry (61)](https://blog.epectec.com/topic/electronics-industry) - [User Interfaces (55)](https://blog.epectec.com/topic/user-interfaces) - [Quality Solutions (33)](https://blog.epectec.com/topic/quality-solutions) - [Flexible Heaters (31)](https://blog.epectec.com/topic/flexible-heaters) - [Events, Training, and Support (9)](https://blog.epectec.com/topic/events-training-and-support) - [RF Products (7)](https://blog.epectec.com/topic/rf-products) - [CNC Machining (3)](https://blog.epectec.com/topic/cnc-machining) - [Fans & Motors (1)](https://blog.epectec.com/topic/fans-motors) See All --- --- ### Need Help with A Project? 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