When it comes to complex electronic systems in aerospace, medical, industrial, and defense applications, precision-engineered cable assemblies are not optional—they’re mission critical.
At Xact, we don’t just build custom cable assemblies—we engineer them from the ground up with precision, reliability, and manufacturability in mind. Our end-to-end engineering support ensures your project starts with a solid design foundation and ends with a perfectly built solution, ready for the demands of your application.
Why Engineering-Driven Cable Assemblies Matter
Poorly specified cables or generic off-the-shelf assemblies can lead to EMI issues, signal degradation, premature wear, or failure in the field. That’s why Xact offers a deeply integrated engineering and manufacturing process to deliver solutions that perform.
We provide:
Custom Electrical Schematics
2D Manufacturing Drawings
3D Cable Assembly Models
Pinout Tables and Wire Maps
Design-for-Manufacturability (DFM) Reviews
Bill of Materials (BOM) Structuring
Cable Routing and Connector Analysis
Whether you’re in the early stages of product development or optimizing a mature design, our engineering team helps you avoid costly revisions and ensures your design is ready for production and field deployment.
From Concept to Connector: Xact Engineering Services Include:
2D & 3D Drawings
We produce professional-grade 2D cable drawings for manufacturing and inspection, along with 3D models that integrate seamlessly into your mechanical assemblies.
These assets ensure:
Precise cable routing in tight enclosures
Proper strain relief and bend radius control
Accurate mating to PCBs, sensors, backplanes, and more
Full Documentation Support
We help generate the documentation needed for your quality system, including:
Full pinout tables
Color-coded wiremaps
Part numbering
Revision control strategies
Engineering Integration
Our engineers collaborate with your team to define:
Labeling, overmolding, and strain relief requirements
Routing and assembly best practices
Why Partner with Xact?
When you work with Xact, you get more than just cables—you get a team of electrical and mechanical engineers focused on manufacturability, signal integrity, and performance.
25+ Years of experience across aerospace, defense, medical, and industrial sectors
ISO-certified processes and quality control
Agile support from prototyping to volume production
Transparent communication and free up-front drawings with every quote
Start with a Free Engineered Drawing
Ask us about a free engineered drawings specifically for your application. This drawing isn’t just a picture—it’s a manufacturing-grade document that supports your design process, documentation, and procurement team.
Precision-Engineered Cable Solutions Built for Performance
At XACT EMS, we specialize in designing and manufacturing custom cable assemblies and wire harnesses that deliver exceptional durability and reliability. Our state-of-the-art facility in Calgary, Canada, is equipped with advanced technology and staffed by a team of experienced professionals dedicated to meeting the unique demands of industries such as:
Aerospace & Defense
Oil & Gas
Mining
Industrial Automation
Transportation
Telecommunications
With decades of expertise, we provide both molded and non-molded solutions, ensuring long-term performance in extreme environments.
Advanced Manufacturing for High-Performance Cable Assemblies
Our Calgary facility is designed to support precision engineering and quality-driven manufacturing, allowing us to produce cable assemblies that meet and exceed strict industry standards.
Custom Molded & Non-Molded Harness Solutions
We manufacture both overmolded and non-molded cable harnesses, engineered for:
Enhanced mechanical strength and strain relief
Superior protection against environmental factors like moisture, dust, and chemicals
Long-lasting performance in high-stress applications
Key Capabilities Include:
High- and low-pressure overmolding for custom encapsulation
Ruggedized assemblies designed to withstand mechanical wear and impact
Custom molding solutions for mission-critical applications
Booted harness configurations for easy field servicing
Designed for Harsh and Challenging Conditions
Our cable assemblies are built to endure extreme environmental and operational stresses, making them ideal for applications requiring:
Robust environmental sealing for moisture and chemical resistance
EMI/RFI shielding for signal integrity in high-interference environments
High-voltage insulation for electrical safety and reliability
Durability in extreme temperatures, vibration, and mechanical stress
Rigorous Testing & Quality Control
At XACT EMS, we adhere to stringent testing protocols to guarantee that every cable assembly delivers unmatched reliability and performance in critical applications.
Our In-House Testing Capabilities Include:
Mechanical stress and strain relief testing
Electrical continuity and insulation resistance validation
RF performance and VSWR testing for high-frequency applications
Environmental stress testing, including thermal cycling and humidity resistance
Compliance with aerospace and military standards such as MIL-STD-810 and AS9100D
EMI/RFI shielding validation
High-voltage dielectric withstand and hermetic sealing tests
Our IPC-certified technicians and inspectors ensure every assembly meets the most demanding industry specifications.
End-to-End Engineering, Design & Manufacturing
From initial concept to final production, our in-house engineering and manufacturing team provides seamless, high-quality solutions for even the most complex cable assembly projects.
Our Comprehensive Capabilities Include:
3D modeling and design for rapid prototyping
Custom mold and connector fabrication using advanced CNC machining
Electro-mechanical integration for specialized applications
Tooling development and prototyping for unique interconnect challenges
Collaborative engineering support to ensure functionality and compliance
By keeping design, prototyping, and production in one location, we maintain strict quality control, reduce lead times, and offer cost-effective solutions.
ESD-Safe Manufacturing for Sensitive Electronics
To protect delicate electronic components, we follow strict electrostatic discharge (ESD) safety measures throughout our assembly process—ensuring superior signal integrity and component longevity.
Expertise in High-Complexity Assemblies, Including:
Multi-conductor and high-density wiring solutions
Precision soldering and micro-termination techniques
Shielded and hermetically sealed cable systems
Power and signal distribution harnesses for advanced applications
Certified for Aerospace & Defense Applications
As an AS9100D-certified facility, we meet the rigorous quality standards required for aerospace, military, and defense applications.
Our Aerospace & Defense Capabilities Include:
MIL-SPEC and AS-compliant cable assemblies for military and aviation use
QPL-approved connectors and harnesses
Custom-built solutions for tactical vehicles, avionics, weapons systems, and secure communications
Full traceability and compliance documentation for defense contracts
Cable Assemblies for the Toughest Industries
Our custom-engineered solutions are trusted in some of the most demanding environments worldwide.
Industries We Serve:
Aerospace & Defense – Tactical communications, avionics, high-speed data cables
Oil & Gas – Explosion-proof, corrosion-resistant wiring for extreme conditions
Mining – Heavy-duty cables for drilling, extraction, and transport operations
Industrial Automation – Robotics, factory automation, and control systems
Transportation – Ruggedized wiring for rail, off-road, and heavy equipment
Visit Our Calgary Facility & Experience the XACT Difference
We invite engineers, project managers, and procurement teams to tour our Calgary facility and see firsthand how we manufacture high-reliability cable assemblies with precision and expertise.
Our dedicated team is ready to collaborate on custom solutions designed to meet your exact performance and durability requirements—on time and within budget.
📞 Schedule a Tour or Discuss Your Next Project Today!
Let’s connect and explore how XACT EMS can deliver the high-performance cable solutions your industry demands.
At XACT Technologies, our state-of-the-art manufacturing facility in Houston, Texas stands as a trusted leader in custom cable assembly and harness manufacturing, delivering high-reliability interconnect solutions for the world’s most demanding industries. Backed by decades of expertise and a commitment to excellence, our team specializes in molded and non-molded cable assemblies engineered to perform flawlessly in the harshest environments, including military, aerospace, mining, oil & gas, transportation, and rugged industrial markets.
See How We Build Mission-Critical Cable Assemblies
Advanced Manufacturing Capabilities for High-Reliability Cable Assemblies
Our Houston facility is equipped with cutting-edge manufacturing technologies and an experienced, IPC-certified team, enabling us to produce precision-engineered cable assemblies that exceed the toughest industry standards.
Molded and Non-Molded Cable Harness Solutions
We specialize in both overmolded and non-molded cable harnesses, engineered for superior mechanical strength, environmental protection, and long-term durability. Our capabilities include:
Low-pressure and high-pressure molding for custom encapsulation and strain relief
Overmolded assemblies that deliver enhanced resistance to mechanical stress, moisture, chemicals, and abrasion
Custom-designed molding solutions for mission-critical and high-performance applications
Complex booted harness assemblies designed for easy serviceability in the field without compromising reliability
Whether your application requires robust environmental sealing, EMI/RFI shielding, or high-voltage insulation, our expert team develops cabling systems built to withstand extreme temperature ranges, vibration, moisture, chemicals, and mechanical wear.
Comprehensive In-House Testing and Quality Assurance
At XACT Technologies, quality and performance are non-negotiable. Every custom cable assembly goes through extensive testing and validation protocols to ensure optimal functionality in mission-critical environments.
Our Testing Capabilities Include:
Mechanical stress and strain relief testing
Electrical continuity and insulation resistance testing
RF performance and VSWR testing for high-frequency applications
Environmental validation, including thermal cycling and moisture resistance
MIL-STD-810 and AS9100D compliance testing
EMI/RFI shielding validation to prevent signal interference
Hermetic sealing and high-voltage dielectric withstand testing
Our IPC-certified technicians and inspectors ensure that each product meets stringent aerospace, military, and industrial specifications—delivering unmatched reliability and peace of mind.
Full-Service Engineering, Design, and Machining — All Under One Roof
From concept to completion, XACT Technologies offers end-to-end engineering and manufacturing services, streamlining the design and production process for even the most complex cable assemblies.
Our In-House Capabilities Include:
3D design and modeling for rapid concept development
Custom mold and connector fabrication using advanced CNC machining
Tooling design and prototyping for unique interconnect challenges
Electro-mechanical integration to meet system-level requirements
Close customer collaboration to ensure performance, functionality, and compliance
By keeping engineering, design, and manufacturing in-house, we maintain complete control over quality, accelerate production timelines, and provide cost-effective, custom-tailored solutions without compromise.
ESD-Safe Manufacturing for Sensitive Electronics
Understanding the critical nature of electrostatic discharge, our facility adheres to strict ESD safety protocols throughout the assembly process—protecting sensitive components and preserving signal integrity.
Specializing in High-Complexity Assemblies:
Multi-conductor and high-complexity wiring configurations
Precision soldering and high-density terminations
Shielded, hermetically sealed cable systems for EMI/RFI protection
Signal and power distribution harnesses for advanced electronics
Certified for Aerospace and Defense Applications
As an AS9100D-certified facility, we are committed to manufacturing solutions that comply with the highest aerospace and defense quality standards.
Key Certifications and Capabilities:
MIL-SPEC and AS-grade cable assemblies for aerospace and military use
QPL-approved connectors and harnesses
Custom-built assemblies for military vehicles, avionics, weapon systems, and secure communications
Full traceability and documentation for defense contracting compliance
Built to Perform in the Harshest Environments
Our ruggedized cable assemblies are trusted in some of the most extreme operating environments worldwide. Whether it’s the battlefield, the oilfield, or the flight deck, our solutions deliver unmatched durability and performance.
Industries We Serve:
Military & Defense – Tactical communication systems, vehicle wiring, avionics, weapons platforms
Aerospace – High-speed data cables, EMI-shielded harnesses, cockpit systems
Mining & Oil & Gas – Explosion-proof, corrosion-resistant, and armored cordsets for hazardous locations
Transportation – Heavy-duty, vibration-resistant wiring for rail, off-road, and industrial vehicles
Industrial Automation – Robotics, control systems, and factory automation in demanding environments
Visit Our Houston Facility — See the XACT Technologies Difference
We welcome engineers, program managers, and sourcing teams to tour our Houston, Texas facility and see firsthand how we bring high-reliability cable assemblies to life. Our dedicated team is ready to collaborate with you on tailored solutions that meet your exact requirements—on time and on budget.
Schedule a Visit or Start a Project Today
If you’re looking for a trusted partner in custom cable manufacturing with deep expertise in aerospace, defense, oil & gas, and industrial markets, let’s connect.
Contact us today to schedule a tour or discuss your next project!
In military operations, speed, reliability, and durability are critical — equipment must be deployed quickly and securely without compromising performance. Xact EMS, an AS9100-certified and CMMC Level 2-compliant manufacturer, delivers custom overmolded military connectors engineered to simplify installation while withstanding the toughest mission environments.
Our overmolded connector solutions streamline field deployment by eliminating the need for secondary strain relief components, reducing installation time and complexity. These connectors feature a ruggedized, professional finish that delivers lasting durability and reliable electrical performance under extreme battlefield, aerospace, and naval conditions.
Advantages of Overmolded Connectors from Xact EMS:
Faster, Simplified Installation – Integrated strain relief reduces setup time and effort.
Rugged Field-Ready Design – Withstands harsh mechanical, environmental, and chemical exposure.
Clean, Professional Appearance – Sleek overmolded finish ideal for high-visibility and mission-critical equipment.
Long-Term Reliability – Protects against vibration, shock, EMI, moisture, and contaminants.
Military-Grade Connectors We Commonly Support:
MIL-DTL-38999 – High-performance circular connectors with EMI shielding for aerospace, defense, and communications.
MIL-DTL-5015 – Rugged power and signal connectors for military vehicles, weapons systems, and ground support.
MIL-DTL-26482 – Compact bayonet-style connectors used in avionics, radios, and tactical gear.
MIL-DTL-83513 (Micro-D) – Miniature high-density connectors for UAVs, drones, and portable electronics.
MIL-DTL-24308 (D-Sub) – Durable data and signal connectors found in military computers, control panels, and comms systems.
MIL-DTL-83723 – Hybrid connectors built for high-vibration, high-temperature environments like aircraft and ground vehicles.
ARINC 600 & 404 – Modular aerospace-grade connectors for military avionics and navigation platforms.
VG95234 – Reverse bayonet connectors used in battlefield communication and command equipment.
Built for Modern Military Systems:
Whether it’s combat-ready vehicles, naval platforms, airborne systems, or tactical communications, Xact EMS delivers fully customized overmolded solutions engineered to meet the strict performance and durability standards required by today’s defense technologies.
From military aviation and naval defense to secure battlefield communication networks, our connectors ensure mission success through dependable, fast-deploy solutions.
Overmolded circular connectors enhance performance by shielding against electromagnetic interference (EMI), providing strain relief, mechanical reinforcement, and environmental protection. These connectors ensure secure electrical connections, maintaining signal integrity and reliable data transmission in mission-critical applications.
Amphenol Circular Connector Series
62GB – Compact, multi-contact connectors with bayonet coupling for dependable AC/DC connections.
62IN Series – Environmentally resistant connectors with a three-point bayonet coupling, ideal for military and industrial applications.
97B Reverse Bayonet – MIL-DTL-5015 compliant connectors with quick-lock bayonet coupling for enhanced shock and vibration resistance.
Amphe-Ex – Explosion-proof connectors designed for hazardous environments, compatible with copper, coaxial, and fiber optics.
Amphe-GTR – High-power, IP67-rated connectors featuring RADSOK® technology, capable of handling up to 120A.
Amphe-HST – Heat shrink tubing solutions resistant to chemicals and solvents, available in various shrink ratios.
Amphe-Lite – Composite-bodied connectors based on 38999 Series III, optimized for extreme environments.
Cable Joiner & FICX – Quick-install cable joiners designed for various wire sizes and applications.
Ceres – Waterproof circular connectors available in multiple sizes for enhanced environmental protection.
CMB – MIL-DTL-26482 Series 1 compliant metal bayonet connectors for power and signal transmission.
Coaxial Inserts – Size 8 coaxial inserts tailored for DIN and D-Sub applications.
CONEC IP67 Power Bayonet – Industrial-grade connectors with bayonet locking for secure, high-strength connections.
CONEC M12x1 Bayonet Quick Locking – Quick-locking M12 connectors for fast and reliable installation.
CONEC M12x1 X-Coding – High-speed data connectors optimized for industrial networking applications.
DHR Downhole Rotatable – High-temperature, rotatable connectors built for harsh downhole environments.
Common Applications
Aerospace Avionics – High-reliability connectors for aircraft communication, navigation, and flight control systems.
Medical Monitoring – Precision-engineered interconnects for patient monitoring devices, diagnostic equipment, and wearable medical technology.
Industrial Control Systems – Rugged connectors designed for automation, PLCs, and factory machinery.
Renewable Energy Systems – Durable, weather-resistant solutions for solar power, wind turbines, and energy storage applications.
Military-Grade Electronics – Mission-critical interconnects for defense communication, radar systems, and tactical equipment.
For precision-engineered, high-performance solutions, Xact EMS is your trusted partner for custom overmolded circular connectors.
Overmolding significantly improves the sealing performance of circular connectors, protecting them from water, chemicals, and extreme temperatures. This makes them ideal for demanding outdoor and industrial applications where exposure to harsh conditions is unavoidable.
Amphenol Circular Connector Series
62GB – Compact, multi-contact connectors with bayonet coupling for secure AC/DC connections.
62IN Series – Environmentally resistant connectors with three-point bayonet coupling, ideal for military and industrial applications.
97B Reverse Bayonet – MIL-DTL-5015 compliant connectors with quick-lock bayonet coupling for superior shock and vibration resistance.
Amphe-Ex – Explosion-proof connectors designed for hazardous environments, compatible with copper, coaxial, and fiber optics.
Amphe-GTR – High-power, IP67-rated connectors featuring RADSOK® technology, supporting up to 120A.
Amphe-HST – Heat shrink tubing solutions resistant to chemicals and solvents, available in multiple shrink ratios.
Amphe-Lite – Composite-bodied connectors based on 38999 Series III, optimized for extreme environments.
Cable Joiner & FICX – Quick-install cable joiners designed for various wire sizes and applications.
Ceres – Waterproof circular connectors available in multiple sizes for enhanced environmental protection.
CMB – MIL-DTL-26482 Series 1 compliant metal bayonet connectors for power and signal transmission.
Coaxial Inserts – Size 8 coaxial inserts tailored for DIN and D-Sub applications.
CONEC IP67 Power Bayonet – Industrial-grade connectors with bayonet locking for secure, high-strength connections.
CONEC M12x1 Bayonet Quick Locking – Quick-locking M12 connectors for fast and reliable installation.
CONEC M12x1 X-Coding – High-speed data connectors optimized for industrial networking applications.
DHR Downhole Rotatable – High-temperature, rotatable connectors built for harsh downhole environments.
Custom Overmolded Solutions by XACT EMS
XACT EMS specializes in designing and manufacturing custom overmolded circular connectors tailored to the specific demands of various industries. Our advanced engineering ensures superior durability, reliability, and long-term performance, making us a trusted provider of mission-critical connectivity solutions.
Industries & Applications
Our overmolded Amphenol connectors provide rugged, high-performance connectivity in challenging environments, including:
Oil & Gas – Reliable interconnects for drilling, exploration, and refinery operations.
Defense – Rugged connectors designed for military vehicles, communication systems, and mission-critical equipment.
Medical Imaging – Precision-engineered solutions for MRI, CT scanners, and diagnostic devices.
Agricultural Equipment – Durable connectors for heavy machinery, GPS systems, and automated farming technology.
Automotive Manufacturing – High-reliability interconnects for robotics, assembly lines, and production automation.
Overmolding enhances the strength and longevity of circular connectors by forming a protective shield against moisture, dust, extreme temperatures, and mechanical stress. This ruggedized design ensures reliable performance in mission-critical applications where durability is essential.
Amphenol Circular Connector Series
Xact EMS specializes in overmolded solutions for a variety of Amphenol circular connectors, designed to meet the needs of demanding industries:
62GB – Compact, multi-contact connectors with bayonet coupling for AC/DC applications.
62IN Series – Environmental-resistant connectors with three-point bayonet coupling, widely used in military and industrial settings.
97B Reverse Bayonet – MIL-DTL-5015 compliant connectors with quick-lock bayonet coupling for superior shock and vibration resistance.
Amphe-Ex – Explosion-proof connectors built for hazardous environments, compatible with copper, coaxial, and fiber optics.
Amphe-GTR – High-power, IP67-rated connectors featuring RADSOK® technology, supporting up to 120A.
Amphe-HST – Chemical and solvent-resistant heat shrink tubing solutions available in multiple shrink ratios.
Amphe-Lite – Rugged, composite connectors based on 38999 Series III, built for extreme environments.
Amphe-PD™ – Touch-proof, rectangular high-power connectors with push-pull coupling for secure connections.
Amphe-Phase – High-current, single-pin connectors with IP2X finger-proof protection and bayonet locking.
Xact EMS delivers precision-engineered overmolded circular connectors, designed to withstand harsh conditions while ensuring consistent, long-term reliability. Our team tailors each solution to meet specific industry requirements, guaranteeing optimal performance.
Industries & Applications
Our overmolded Amphenol connectors are trusted across a range of high-performance industries, including:
Industrial automation – Reliable connectivity solutions for factory automation and robotics.
Aerospace – Rugged interconnects for avionics, satellites, and defense systems.
Military & defense – Battle-tested solutions for ground vehicles, tactical communication, and ruggedized equipment.
Medical devices – Precision-engineered connectors for diagnostic and life-saving medical technologies.
Transportation – High-performance interconnects for automotive, rail, and electric vehicle applications.
Renewable energy – Weather-resistant connectors for solar, wind, and energy storage systems.
With uncompromising quality and advanced engineering, Xact EMS provides overmolded solutions that deliver unmatched performance and reliability in the most demanding environments.
Xact EMS: Precision-Engineered Cable Assemblies & Overmolded Military Connectors
Xact EMS is a leading AS9100-certified and CMMC Level 2-compliant manufacturer specializing in custom cable assemblies and interconnect solutions for defense, aerospace, and high-reliability applications. With state-of-the-art production facilities in the United States and Canada, we deliver mission-critical connectivity solutions that meet the most stringent military standards.
Overmolded Military Connectors: Engineered for Extreme Conditions
Our expertise in overmolding military-grade connectors ensures superior durability, protection, and reliability in demanding environments. Overmolding creates a seamless, ruggedized barrier that enhances mechanical strength while shielding against:
Extreme temperatures – Withstands harsh thermal fluctuations in aerospace and battlefield conditions.
Moisture & contaminants – Provides a watertight seal against dust, chemicals, and humidity.
Shock & vibration – Absorbs impact forces to maintain uninterrupted connectivity in high-motion applications.
EMI/RFI interference – Reduces electromagnetic interference for secure, noise-free signal transmission.
Military-Grade Connectors We Overmold
We specialize in overmolded solutions for a wide range of military and aerospace connectors, including:
MIL-DTL-38999 – High-performance circular connectors with EMI shielding for aerospace and ground systems.
MIL-DTL-5015 – Rugged power and signal connectors ideal for military vehicles and heavy equipment.
MIL-DTL-26482 – Compact, bayonet-coupled connectors used in avionics and tactical communications.
MIL-DTL-83513 (Micro-D) – Miniature, high-density connectors designed for UAVs, missile systems, and portable electronics.
MIL-DTL-24308 (D-Sub) – Durable data and signal connectors for military control systems and computing platforms.
MIL-DTL-83723 – Hybrid connectors built for high-vibration aerospace and ground applications.
ARINC 600 & 404 – Modular aviation connectors for military avionics and secure communications.
VG95234 – Reverse bayonet connectors commonly used in military radio and communications systems.
Trusted for Mission-Critical Applications
Xact EMS overmolded solutions enhance performance in demanding military and aerospace environments, ensuring secure, uninterrupted signal transmission for:
Military ground vehicles – Tanks, armored personnel carriers (APCs), and tactical transport.
Avionics & aerospace – Fighter jets, drones, and satellite communication systems.
Radar & sensor systems – Secure battlefield intelligence and surveillance networks.
Naval & marine defense – Shipboard power and communications infrastructure.
Secure data transmission networks – High-speed, interference-resistant military communication links.
With a commitment to quality, reliability, and innovation, Xact EMS delivers battle-proven connectivity solutions that exceed military specifications and keep critical operations running flawlessly.
