Cost & Sourcing
Custom Cable Assembly Cost Drivers
Cost is driven by the build definition: cable construction, connector choice, termination labor, overmolding, custom extrusion, testing, documentation, packaging, and quantity. A complete drawing package helps MTTJ price the real work instead of assumptions.
Published: Updated:
Decision summary
What to carry into the decision
- Cost follows the controlled build: materials, terminations, tooling, assembly steps, tests, records, packaging, and demand pattern.
- Separate one-time costs from recurring unit scope before comparing quotations.
- A lower component line may reflect a different manufacturer, substitution rule, or availability assumption.
In this guide
- 1Direct answer
- 2Common cost variables
- 3Make supplier quotes comparable
- 4RFQ information that reduces rework
- 5Compare total landed inputs
- 6Normalize the cost stack
- 7Common cost‑comparison errors
Use the sections in sequence, then turn the open items into one controlled build or sourcing package.
Direct answer
The largest cost drivers are usually material selection, connector availability, the number of termination steps, overmolding or tooling, required tests, required records, and order quantity.
The RFQ should separate required features from optional preferences so sourcing, tooling, labor, and inspection can be estimated consistently.
Common cost variables
The same visible cable length can have very different cost when construction, connectors, and tests change.
| Materials | Wire gauge, conductor count, shielding, jacket, filler, color, and marking. |
|---|---|
| Components | Specified connectors, terminals, housings, grommets, sleeves, labels, and accepted equivalents. |
| Processes | Cutting, stripping, crimping, soldering, shielding, overmolding, routing, inspection, and packing. |
| NRE and tooling | Fixtures, applicators, molds, gauges, programs, first-article work, and validation samples. |
| Tests and records | Fixtures, cycle time, sampling, inspection reports, test records, material documents, and shipment records. |
| Packing and delivery | Labels, reels or trays, export packing, shipment terms, destination, and import-side cost inputs. |
Make supplier quotes comparable
Use the same drawing revision, BOM, approved-equivalent rules, quantity breakpoints, test plan, record package, packing method, and delivery destination for every quote.
Separate recurring unit work from one-time tooling, fixtures, validation, programming, and first-article activity. A lower unit price is not comparable when it excludes required NRE, tests, records, packing, or delivery inputs.
RFQ information that reduces rework
MTTJ can evaluate the same drawing more quickly when cost-driving details are visible together.
- Drawing revision, sample status, target quantity, and expected production stage.
- No-substitution components and components where equivalent sourcing is acceptable.
- Test method, fixture needs, voltage or pressure values, dwell time, and pass/fail criteria.
- Packing, labeling, destination market, and required record format.
Compare total landed inputs
Compare component and conversion cost together with NRE, tooling custody and transfer rights, validation work, packing, freight, insurance, brokerage, duties or taxes confirmed by the importer, inventory policy, and the cost of engineering changes.
Material availability, timing, required documents, and production planning are confirmed against the quoted drawing, supplier evidence, quantity, and order requirements. Do not apply a fixed savings assumption across assemblies with different BOMs or validation scope.
Normalize the cost stack
Use the same build revision and commercial period for each quote.
| Direct material | Wire or cable, connectors, terminals, seals, labels, protection, and packaging. |
|---|---|
| Conversion | Cutting, stripping, crimping, soldering, routing, overmolding, assembly, and inspection. |
| Non‑recurring | Tooling, fixtures, setup, samples, and separately scoped qualification work. |
| Program and delivery | Demand pattern, records, change handling, packing, freight term, destination, and inventory assumptions. |
Common cost-comparison errors
Do not compare different drawing revisions, hide tooling inside unit price, assume every connector quote uses the same source, or omit test and packaging scope. Those differences can be larger than a visible labor-rate difference.
