Custom Cable Assemblies
Custom cable assembly for your application
From the technical requirement to series production: TTL develops customer-specific connectivity solutions for demanding applications and realises them through its production network.
- Founded
- 2001
- Custom cable assemblies successfully realised
- over 7,500
- Well-known companies in industry & medical technology supported
- over 1,500
Why TTL Network for your custom cable assemblies?
From small batches to high volumes
Tailored solutions for different quantities.
Engineering expertise
10,000+ technical drawings and 1,000 customer-specific tools.
Manufacturer-independent solution development
Components and production matched to requirements, cost and lead time.
Tested quality
Mechanical, electrical, optical and application-specific test methods.
From idea to series production
Technical support throughout the entire development process.
Case Studies
Be inspired by successful projects and discover what our solutions make possible.
Professional AV & Events
TTL Lan® UltraFlex™ Cat.6A S/FTP patch cable
To install several DSP loudspeaker systems in a 360° cinema, the customer needed a flexible Cat.6A patch cable with a small bend radius and UL approval.
Learn more
Medical Technology
TTL Premium UltraFlex HDMI 2.0 cable
The customer was looking for an HDMI cable that transmits the high-resolution images of the FotoFinder ATBM master without errors and meets high EMC immunity requirements.
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Medical Technology
TTL Premium UltraFlex HDMI-to-DVI cable
The customer was looking for a reliable HDMI-to-DVI cable for endoscopy cameras – without signal dropouts caused by movement or accidental disconnection from the socket.
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Machinery & Plant Engineering
MDP4 power cable
G&D’s KVM solutions are used in mission-critical environments, where permanent availability of the devices is essential.
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Companies that trust us
Our approach
Step by step to a tailored solution
From the first requirement to reproducible series production, we guide your project through a clearly defined development and approval process.
01
Requirements analysis
Together we define:
- Technical and commercial parameters
- Specifications and application requirements
02
Concept
We develop:
- A detailed solution proposal in the form of a technical data sheet
- A clear and understandable basis for alignment with your team
03
Prototyping
We deliver:
- First prototypes once the concept has been approved
- Validation samples for testing in your specific application environment
04
Approval
Depending on project requirements:
- Preparation of first article inspection reports (FAI reports)
- Retention of golden samples for long-term quality assurance
Change loop
- Sampling
- Change
- Re-sampling
- Approval and pre-series
After sampling, the project moves into pre-series – or into a change that goes through the same process again.
05
Production
Our quality assurance:
- Production to the requirements and standards defined for each project
- Defined testing and approval processes to ensure reproducible series quality
06
Delivery
We offer:
- Coordinated delivery and call-off models
- Framework agreements with flexible call-offs from our central warehouse in Halle (Westfalen)
- Comprehensive after-sales support
Connectivity solutions
Our solution competencies
Technical capabilities
Our capabilities, your advantage
Our technical capabilities are as diverse as your challenges.
Bulk cable
Individually matched to the application
- Individual choice of materials
- Approvals to international standards, depending on project requirements
- Properties that meet specific requirements such as flexibility or temperature resistance
- Clear and durable marking
Termination technology
Precision down to the last detail
- Crimping
- Soldering
- IDC
- Automated series production
Connectors
Standard or custom
- Industry standards
- Complementary types
- Individual custom designs
Customer-specific overmoulding
Protection and design to customer specification
- Overmoulding for connectors, ferrite cores and Y-splitters
- Other shapes
Sub-assembly
Everything from a single source
- Processing of customer-supplied components
Marking technology
Clear and durable
- Printing
- Labels
- Laser engraving
Injection-moulded parts
Robust and precisely made
- Plastic components
- Zinc and aluminium die casting
Customer-specific packaging solutions
Matched to product and logistics
- Packaging and labelling to suit logistics, handling and customer requirements
- Environmentally friendly materials and packaging are also available
Project examples
Assembly Examples
Customised solutions for a wide range of interfaces
Whether DisplayPort, USB, Ethernet, circular connectors or wire-to-board: discover selected examples of individually configured connectivity solutions that we have realised for a wide range of technical requirements.
Precisely tested for reliable connections
Depending on the product and project requirements, mechanical, electrical, optical and application-specific test methods are used. This is how we verify defined quality and performance requirements before series production. Depending on the application, product type and project requirements, the following test methods, among others, can be used:
Mechanical tests
- Mating cycle tests for durable connections.
- Drag chain tests for moving applications.
- Torsion and bending tests, also under controlled climatic conditions.
Fire behaviour tests
- UL- and IEC-compliant flame tests.
- CPR fire class tests for legal requirements.
Optical tests
- Microscopic examinations for quality control.
- Cross-section analysis of connector terminations.
Electrical tests
- Impulse voltage tests to verify insulation strength.
- Pin-to-pin continuity tests.
Special tests
- Ageing and thermal cycling tests for long-term validation.
Mechanical tests 
Fire behaviour tests 
Optical tests 
Electrical tests
Technology that connects
“What matters to us is truly understanding the technical requirement. Only then do we develop a solution together with the customer that can be reliably implemented in series production.”
Frequently asked questions about samples and prototypes
- Does TTL also supply prototypes and small batches?
- Yes. From small batches to high volumes, we develop tailored solutions for different quantities. Once the concept has been approved, first prototypes and validation samples are produced for testing in your specific application environment. Production is project-specific, through specialised production partners in our international network. They are selected on the basis of technical, quality and commercial requirements; our production partners are audited as part of our supplier management. We take project-specific certification requirements into account when selecting the appropriate manufacturing partner.
- Can a sample go straight into series production?
- Yes, as soon as the sample has been approved. Depending on project requirements, on approval we prepare first article inspection reports (FAI reports) and retain golden samples for long-term quality assurance. Defined testing and approval processes support reproducible series quality. If changes are needed after sampling, the modified sample goes through the same process until approval.
- How quickly can I get a sample?
- As a rule, your sample is ready after around 4 to 6 weeks. Once the concept has been approved, first prototypes and validation samples are produced for testing in your application environment. If changes are needed after sampling, the modified sample goes through the same process until approval – only then does it go into series production.
- What happens if a connector is not available?
- We develop independently of manufacturers: we select components and production to match requirements, cost and lead time. In addition to industry-standard connectors, we use complementary types and individual custom designs. Like any change, a different connector goes through re-sampling before it is adopted for series production.
Expertise and experience you can rely on
Our team of experienced technical consultants supports you in every phase of your project.
What we need for your enquiry
- Your task and industry – one sentence is enough
- Operating environment and application requirements
- Quantity: sample, small batch, series production or recurring demand
- Connectors and interfaces, such as M12 X-coded
- Lengths and marking to your specification
- Drawing or specification, if available – not required to get started
Free initial consultation
In around 30 minutes, we capture your requirements in detail, ask targeted questions and present tailored solutions.
Guided implementation
From the first conversation to the final solution, our experts are at your side as your dedicated contact – following our proven approach for custom cable assemblies.
- Mon–Thu 08:00–17:00
- Fri 08:00–14:00
- +49 5201 85660-00
- info@ttl-network.de
No custom solution needed?
Many requirements can already be met with our own brands TTL Lab®, TTL Live®, TTL Link® and TTL Lan® – available from stock in Halle (Westfalen).