At XACT EMS, our state-of-the-art manufacturing facility in Houston, Texas is a trusted leader in custom cable assembly and harness manufacturing, delivering high-reliability interconnect solutions for the world’s most demanding industries. With decades of expertise and a commitment to excellence, we specialize in molded and non-molded cable assemblies engineered to withstand the harshest environments, including military, aerospace, mining, oil & gas, transportation, and rugged industrial applications.
Advanced Manufacturing for High-Reliability Cable Assemblies
Our Houston facility is equipped with the latest manufacturing technologies and a team of IPC-certified experts, allowing us to produce precision-engineered cable assemblies that exceed the toughest industry standards.
Molded and Non-Molded Cable Harness Solutions
We design and manufacture overmolded and non-molded cable harnesses 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 for enhanced resistance to mechanical stress, moisture, chemicals, and abrasion
- Custom-designed molding solutions for mission-critical applications
- Booted harness assemblies designed for easy serviceability without sacrificing reliability
Precision Engineering for Harsh Environments
Our cable assemblies are built to endure extreme temperatures, vibration, moisture, chemicals, and mechanical wear. Whether your application requires:
- Robust environmental sealing
- EMI/RFI shielding
- High-voltage insulation
Our expert team delivers solutions that meet the most demanding performance requirements.
Comprehensive In-House Testing & Quality Assurance
At XACT EMS, quality is non-negotiable. Every custom cable assembly undergoes rigorous testing and validation 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 (thermal cycling, 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 ensure every product meets aerospace, military, and industrial specifications, delivering unmatched reliability and peace of mind.
Full-Service Engineering, Design & Machining—All Under One Roof
From concept to completion, XACT EMS provides end-to-end engineering and manufacturing, 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 with advanced CNC machining
- Tooling design and prototyping for unique interconnect challenges
- Electro-mechanical integration for system-level requirements
- Close customer collaboration to ensure performance, functionality, and compliance
By keeping engineering, design, and manufacturing in-house, we maintain complete quality control, accelerate production timelines, and provide cost-effective, custom solutions without compromise.
ESD-Safe Manufacturing for Sensitive Electronics
We follow strict ESD safety protocols to protect sensitive components and maintain signal integrity throughout the assembly process.
Specializing in High-Complexity Assemblies:
- Multi-conductor and high-density wiring configurations
- Precision soldering and termination
- Shielded, hermetically sealed cable systems for EMI/RFI protection
- Signal and power distribution harnesses for advanced electronics
Certified for Aerospace & Defense Applications
As an AS9100D-certified facility, we manufacture cable assemblies that comply with the highest aerospace and defense quality standards.
Key Certifications & Capabilities:
- MIL-SPEC and AS-grade cable assemblies for aerospace and military applications
- 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 for the Harshest Environments
Our ruggedized cable assemblies are trusted in extreme operating environments worldwide. Whether in the battlefield, oilfield, or 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—Experience the XACT Technologies Difference
We invite engineers, program managers, and sourcing teams to tour our Houston, Texas facility and see firsthand how we manufacture high-reliability cable assemblies. Our team is ready to collaborate on custom solutions tailored to your exact requirements—on time and on budget.
Schedule a Visit or Start a Project Today
Looking for a trusted partner in custom cable manufacturing with expertise in aerospace, defense, oil & gas, and industrial markets?
📞 Contact us today to schedule a tour or discuss your next project!
