You’re scaling wire harness production from hundreds to thousands of assemblies monthly. Your current manual crimping process can’t support the volume. You need flat cables, FRC connectors, and Berg strips in consistent supply—plus automation support to scale production without proportionally scaling labor costs.
OX Connections provides comprehensive flat cable assembly solutions: Berg strips, FRC connectors, and grey flat cables across all standard pitches (0.635mm, 1mm, 1.27mm, 2mm, 2.54mm) with extensive stock of Neltron and OX branded connectors covering 6-64 pin configurations. We also support automated flat cable crimping for high-volume wire harness production.
Berg Strip Connectors: Complete Pitch Range Ex-Stock
Berg strips (male pin headers) provide the mating interface for FRC female connectors in flat cable assemblies. The pins mount on PCBs, creating connection points for ribbon cable harnesses throughout control panels, industrial equipment, and electronic assemblies.
Available Pitches:
1mm Pitch Berg Strips: Ultra-compact pin spacing for high-density PCB applications. Used in space-constrained electronics, compact industrial modules, and applications requiring maximum connection density in limited board area. Pin counts typically 6-40 positions.
1.27mm Pitch Berg Strips: Standard pitch for flat ribbon cable applications balancing connection density with manufacturing practicality. Widely used across consumer electronics, industrial control boards, and general-purpose PCB interconnections. Pin counts from 6-64 positions available.
2mm Pitch Berg Strips: Intermediate pitch providing easier assembly than 1mm/1.27mm while maintaining reasonable connection density. Common in industrial equipment, test equipment, and applications where assembly ease matters. Pin counts 6-50 positions typical.
2.54mm Pitch Berg Strips: Standard 0.1-inch pitch matching breadboard and prototype board spacing. Universal compatibility with development tools, evaluation boards, and production PCBs using standard spacing. Most extensive pin count range available: 6-64 positions.
All Berg strips available in:
- Through-hole mounting for wave soldering or hand assembly
- Surface mount (SMD) versions for automated PCB assembly
- Single row and dual row configurations
- Standard and long pin options for specific assembly requirements
FRC Connectors: Comprehensive Stock Across All Configurations
FRC (Flat Ribbon Cable) connectors terminate ribbon cables, creating organized wire harnesses for internal equipment wiring. OX maintains extensive FRC connector stock across pitches, pin counts, and connector types.
Pitch and Pin Configuration Coverage:
1.25mm Pitch: 6-40 pin configurations for ultra-compact applications
2.00mm Pitch: 6-60 pin configurations for balanced density/assembly
2.54mm Pitch: 6-64 pin configurations for maximum compatibility
The FRC Connector Types Available:
FRC Female with Strain Relief (SR): Standard IDC female connectors with integrated strain relief providing cable retention and stress distribution. The strain relief clamps the cable jacket, preventing wire pullout under handling or vibration. Most common connector type for general flat cable assemblies.
Box Header Straight: Male shrouded headers mounting perpendicular to PCB surface. The shrouded housing provides polarization preventing reverse insertion and physical protection for pin contacts. Used when cable assembly connects vertically to PCB.
Box Header Right Angle (R/A): Male shrouded headers mounting parallel to PCB surface. Cable exits parallel to board, reducing overall assembly height and improving cable routing in compact enclosures. Common in space-constrained equipment and stackable PCB assemblies.
SMD Type FRC: Surface mount connectors for automated PCB assembly. Eliminates through-hole soldering requirements, enabling full SMT production lines. Used in high-volume production where automated assembly efficiency matters.
Ejector Type (Straight and Right Angle): Connectors with integrated ejector mechanism facilitating cable removal without damaging connector or cable. Critical for applications requiring frequent connection/disconnection during testing, maintenance, or field service. Available in both straight and right-angle orientations.
Transition Connectors: Specialized connectors routing flat cable from one pitch to another or converting between connector types. Enables system integration when mixing different cable pitches or connector standards within single assembly.
Brands Available:
Neltron: Taiwan-manufactured FRC connectors with proven quality and zero rejection track record. Neltron connectors provide consistent performance for OEMs requiring reliable flat cable assemblies. (OX is the only authorized Neltron distributor in India.)
OX Brand: Cost-effective FRC connectors manufactured to industrial standards with RoHS certification. OX branded connectors provide competitive pricing for high-volume production while maintaining functional reliability.
Grey Flat Cables: Complete Pitch Coverage
Grey flat ribbon cables provide organized multi-conductor wiring for internal equipment connections. The flat geometry enables organized cable routing, easy wire counting, and efficient use of panel space compared to round multi-conductor cables.
Available Pitches:
0.635mm Pitch Flat Cable: Ultra-fine pitch for maximum conductor density. Used in compact electronics requiring many connections in minimal space. Conductor counts typically 10-40 conductors.
1mm Pitch Flat Cable: High-density flat cable balancing conductor count with cable flexibility and assembly practicality. Common in consumer electronics, compact industrial modules, and applications prioritizing connection density. Conductor counts 10-50 positions.
1.27mm Pitch Flat Cable: Standard flat cable pitch matching 1.27mm FRC connectors and Berg strips. Most widely used pitch across industrial and commercial applications. Conductor counts from 6-64 conductors available in stock.
Cable Construction:
Standard grey PVC insulation providing adequate electrical isolation and mechanical protection for internal equipment wiring. Color-coded conductors (grey with colored stripe or edge marking) facilitate wire identification during assembly and troubleshooting.
Conductor gauge typically 28 AWG providing balance between current capacity (approximately 1-2A per conductor) and cable flexibility. Suitable for signal connections, low-power distribution, and control wiring.
Cables available in standard lengths or custom cut to specification for wire harness production. Stock lengths enable immediate availability; custom lengths support specific assembly requirements.
Automated Flat Cable Crimping for Wire Harness Production
Manual crimping of FRC connectors works for prototype quantities and low-volume production. Scaling to hundreds or thousands of assemblies monthly requires automation to maintain quality, reduce labor costs, and improve production efficiency.
Flat Cable Crimping Machine Support:
OX provides access to automated flat cable crimping equipment for high-volume wire harness orders. Automated crimping offers:
Consistent Quality: Machine crimping maintains uniform contact insertion force across all pins, eliminating variation from manual assembly. Every connector receives identical crimping force, ensuring reliable electrical connections and mechanical retention.
Production Speed: Automated crimping processes cables in seconds versus minutes for manual assembly. Production capacity scales without proportionally increasing labor requirements. High-volume orders complete in days rather than weeks.
Labor Cost Reduction: Automation replaces repetitive manual labor with machine operation. One operator can supervise multiple crimping cycles, dramatically improving labor efficiency for high-volume production.
Quality Verification: Automated systems can integrate quality checking—verifying proper cable insertion, confirming pin engagement, detecting missing conductors before connector crimping completes.
Wire Harness Production Capability:
For OEMs requiring assembled flat cable harnesses—cable cut to length, connectors crimped on one or both ends, tested and packaged—OX supports production from samples to thousands of assemblies. This eliminates your need to invest in crimping equipment, train assembly personnel, or manage flat cable inventory for internal assembly.
Provide harness specifications (cable pitch, conductor count, length, connector types on each end), and OX can quote assembled harness production with lead times supporting your production schedules.
Applications Across Multiple Industries
Industrial Control Panels: Flat cable harnesses connect I/O modules, PLCs, power supplies, and interface boards inside control panels. The organized flat cable routing simplifies panel wiring compared to individual wires, reduces assembly time, and facilitates troubleshooting. Panel builders assembling multiple units benefit from pre-made harnesses arriving ready for installation.
Consumer Electronics Manufacturing: Internal connections in consumer products—display connections, control board interfaces, power distribution—use flat cables extensively. High-volume consumer electronics production requires consistent component supply and often benefits from outsourced harness assembly.
Test Equipment: Instrumentation and test equipment use flat cables for internal module interconnections. Compact packaging, organized routing, and easy serviceability make flat cable assemblies practical for test equipment requiring periodic reconfiguration or maintenance.
Medical Device Electronics: Medical equipment control boards and display interfaces use flat cable connections. RoHS compliance and quality consistency matter for medical device manufacturing. Certified components with test reports support medical device quality processes.
LED Lighting Control: LED lighting controllers, dimming systems, and multi-zone lighting panels use flat cable assemblies for control signal distribution. The compact cable form factor fits lighting fixture housings while supporting multiple control channels.
Building Automation Systems: HVAC controllers, access control panels, lighting control systems use flat cable assemblies for internal wiring. Building automation equipment operates for decades—component reliability affects long-term maintenance costs.
Automotive Electronics: Automotive control modules, display interfaces, and sensor wiring harnesses increasingly use flat cable assemblies where space constraints and assembly efficiency matter. Automotive production volumes benefit from automated harness crimping.
Certifications and Technical Support
RoHS Compliance: All FRC connectors, Berg strips, and flat cables in OX stock comply with RoHS directives. Certification documentation provided supports export requirements and customer compliance specifications.
Test Reports Available: Product testing documentation covering electrical performance, mechanical retention, temperature performance, and other specifications available upon request. Test reports support quality management systems and customer validation requirements.
Technical Datasheets: Complete specifications provided including dimensional data for PCB layout, current ratings, voltage ratings, operating temperatures, and material specifications.
Application Engineering Support: Our team assists with:
- Connector type selection based on assembly requirements
- Cable pitch and conductor count determination
- Harness design optimization for manufacturability
- Crimping automation feasibility for production volumes
Competitive Pricing for Production Volumes
Flat cable assemblies represent substantial cost in many electronic products. Component pricing and harness assembly costs directly impact product margins.
Volume Pricing: Production quantities receive preferential pricing supporting your cost targets. Annual volume commitments enable additional pricing optimization.
Harness Assembly Economics: Outsourced harness assembly with automated crimping often costs less than internal manual assembly when labor costs, equipment investment, and production capacity requirements are factored. Contact us for harness assembly quotations comparing to your internal assembly costs.
Getting Started with Flat Cable Solutions
Contact [email protected] with your requirements:
For Component Stock:
- Pitch needed (0.635mm, 1mm, 1.27mm, 2mm, 2.54mm)
- Pin/conductor count
- Connector types (FRC female, box header, ejector, etc.)
- Quantities for immediate requirement and production
For Wire Harness Production:
- Cable specifications (pitch, conductor count, length)
- Connector requirements (types, one or both ends)
- Assembly quantities (samples to production volumes)
- Quality/testing requirements
- Delivery timeline
What OX Provides:
- Stock availability confirmation
- Competitive pricing for volumes specified
- Harness assembly quotations with lead times
- RoHS certification documentation
- Test reports and technical datasheets
- Application engineering support
- Automated crimping capability for production
For OEMs requiring flat cable components or assembled harnesses—comprehensive stock, automation support, competitive pricing, and complete certifications from OX Connections support your production requirements.