{"id":16710,"date":"2026-09-15T09:00:00","date_gmt":"2026-09-15T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?post_type=case_studies&#038;p=16710"},"modified":"2026-08-26T07:08:27","modified_gmt":"2026-08-26T05:08:27","slug":"how-to-provide-compact-and-high-speed-interconnects-for-networking-switches-and-routers-with-tps-custom-cable-assembly-services","status":"publish","type":"case_studies","link":"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-provide-compact-and-high-speed-interconnects-for-networking-switches-and-routers-with-tps-custom-cable-assembly-services\/","title":{"rendered":"How to Provide Compact and High Speed Interconnects for Networking Switches and Routers with TPS Custom Cable Assembly Services?"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>For system integrators, panel builders, and procurement teams in the networking industry, the internal cabling of switches and routers is not just about connecting point A to point B\u2014it is about maintaining signal integrity at data rates exceeding 25 Gbps while fitting into ever-shrinking chassis footprints. A single poorly routed or improperly terminated cable harness can degrade signal quality, fail EMC testing, and delay product launches.<\/p>\n<p>TPS Elektronik&#8217;s <strong>custom cable assembly services<\/strong> were engaged by an anonymous networking OEM to design and manufacture compact, high-speed internal cable harnesses for their next-generation data center switches and routers\u2014from prototype validation to volume production.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/cable-assembly\/\">Request a custom cable assembly quote \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc\">Table of Contents<\/h2>\n<ol>\n<li><a href=\"#the-challenge\">The Challenge: High-Speed Interconnects in Compact Networking Equipment<\/a><\/li>\n<li><a href=\"#the-solution\">The TPS Solution: Custom Cable Assembly for Networking Applications<\/a><\/li>\n<li><a href=\"#manufacturing-approach\">Manufacturing Approach: Precision and Process Control<\/a><\/li>\n<li><a href=\"#outcomes\">Outcomes: Signal Integrity, Space Savings, and Supply Chain Consolidation<\/a><\/li>\n<li><a href=\"#tps-capabilities\">TPS Custom Cable Assembly Capabilities for Networking Equipment<\/a><\/li>\n<li><a href=\"#faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"the-challenge\">\n<h2>1. The Challenge: High-Speed Interconnects in Compact Networking Equipment<\/h2>\n<p>The customer\u2014an anonymous networking OEM developing next-generation data center switches and routers\u2014faced a critical design challenge: their new platform required internal cable harnesses that could carry high-speed signals with minimal loss and crosstalk, while fitting within the limited internal space of a 1U or 2U chassis. Traditional PCB routing was no longer sufficient; signal paths were becoming too long, and board space was at a premium.<\/p>\n<p>Internal cabled interconnects offer significant advantages over PCB-only routing for high-speed networking equipment. By using cable assemblies to route high-speed signals from processors to other locations on the board, designers can reduce host system board trace lengths, lower PCB costs, and improve signal integrity. For high-density networking applications, flexible interconnect solutions with high-speed cable assemblies support aggregate data rates of 100 Gbps and 200 Gbps.<\/p>\n<p>Key challenges for the customer included:<\/p>\n<ul>\n<li><strong>Signal integrity:<\/strong> Maintaining impedance control and minimizing crosstalk at data rates exceeding 25 Gbps per lane<\/li>\n<li><strong>Space constraints:<\/strong> Routing multiple high-speed differential pairs within the limited internal volume of a 1U chassis<\/li>\n<li><strong>Thermal management:<\/strong> Ensuring cables and connectors could withstand operating temperatures inside densely packed equipment<\/li>\n<li><strong>Reliability:<\/strong> Achieving the mechanical durability required for field service and equipment handling<\/li>\n<\/ul>\n<p>TPS Elektronik was engaged to develop <strong>custom cable assemblies<\/strong> that would deliver the required signal integrity and mechanical reliability while meeting the customer&#8217;s aggressive production timeline.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-16958\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/08\/Pre-Terminated-Rack-Power-Cable-Assembly-for-ORv3-Power-Shelf-1.jpg\" alt=\"Pre-Terminated-Rack-Power-Cable-Assembly-for-ORv3-Power-Shelf Vorkonfektionierte Rack-Stromkabelbaugruppe f\u00fcr ORv3-Stromablage\" width=\"1120\" height=\"600\" \/><\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/cable-assembly\/\">Learn more about TPS custom cable assembly services \u2192<\/a><\/p>\n<\/section>\n<section id=\"the-solution\">\n<h2>2. The TPS Solution: Custom Cable Assembly for Networking Applications<\/h2>\n<p>TPS Elektronik&#8217;s approach combined precision cable assembly manufacturing with design-for-manufacturability (DFM) feedback to deliver internal cable harnesses that met the customer&#8217;s performance and reliability requirements.<\/p>\n<p><strong>Engineering and Design Support:<\/strong><\/p>\n<ul>\n<li><strong>Cable type selection:<\/strong> High-speed twinaxial cables with 100\u03a9 differential impedance for data rates up to 25 Gbps<\/li>\n<li><strong>Connector selection:<\/strong> SFP, SFP+, and QSFP interfaces matching the customer&#8217;s board-level connector footprints<\/li>\n<li><strong>Routing optimization:<\/strong> Cable routing paths designed to minimize bend radius violations and maintain signal integrity<\/li>\n<li><strong>DFM feedback:<\/strong> Review of designs to optimize for manufacturability and reduce assembly time<\/li>\n<\/ul>\n<p><strong>Custom Cable Configurations:<\/strong><\/p>\n<ul>\n<li><strong>Differential pair harnesses:<\/strong> Four to eight differential pairs per cable assembly for high-bandwidth data transmission<\/li>\n<li><strong>SFP\/QSFP cable assemblies:<\/strong> Custom length and connector configurations to match chassis layouts<\/li>\n<li><strong>Breakout cables:<\/strong> QSFP to four SFP+ fan-out harnesses for connecting 40 GbE switches to existing 10 GbE infrastructure<\/li>\n<li><strong>Shielded assemblies:<\/strong> Foil and braid shielding options for EMI control in dense chassis environments<\/li>\n<\/ul>\n<p>For <strong>networking cable assembly<\/strong> applications, TPS&#8217;s in-house DFM support ensured that cable designs were optimized for manufacturing, with proper AWG selection, strain relief, and labeling integrated into the design from the start. TPS also referenced <strong>IEC 61196-1-111<\/strong> and <strong>IEC 61169<\/strong> series standards for coaxial connector performance and phase stability test methods.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-17137\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/08\/PCB-Routing-vs-Internal-Cable-Assembly-Comparison-for-Network-Equipment-1.jpg\" alt=\"PCB Routing vs Internal Cable Assembly Comparison for Network Equipment Vergleich von Leiterplattenf\u00fchrung und interner Kabelkonfektionierung f\u00fcr Netzwerkger\u00e4te\" width=\"1920\" height=\"1079\" \/><\/p>\n<\/section>\n<section id=\"manufacturing-approach\">\n<h2>3. Manufacturing Approach: Precision and Process Control<\/h2>\n<p>TPS Elektronik&#8217;s <strong>custom cable assembly<\/strong> manufacturing process was designed to deliver consistent quality across prototype and production volumes, with full traceability and documentation.<\/p>\n<p><strong>Manufacturing Processes:<\/strong><\/p>\n<ul>\n<li><strong>Precision cutting and stripping:<\/strong> Automated cutting and stripping of high-speed twinaxial cables to exact lengths<\/li>\n<li><strong>Crimping and soldering:<\/strong> Controlled crimping and soldering processes for reliable electrical connections<\/li>\n<li><strong>Shielding termination:<\/strong> Consistent termination of foil and braid shields for EMI control<\/li>\n<li><strong>Labeling and identification:<\/strong> Laser marking, shrink labels, and barcodes for traceability and installation clarity<\/li>\n<li><strong>Strain relief:<\/strong> Over-molding and booting for mechanical durability<\/li>\n<\/ul>\n<p><strong>Quality Control:<\/strong><\/p>\n<ul>\n<li><strong>100% continuity testing:<\/strong> Every conductor in every assembly verified for continuity and correct pin mapping<\/li>\n<li><strong>Impedance verification:<\/strong> Ensuring 100\u03a9 differential impedance for high-speed data transmission<\/li>\n<li><strong>Dielectric withstand testing:<\/strong> Per applicable specifications for insulation integrity<\/li>\n<li><strong>IPC\/WHMA-A-620 Class II\/III compliance:<\/strong> Workmanship standards for cable and harness assemblies<\/li>\n<\/ul>\n<p>TPS Elektronik supports custom cable assemblies with full documentation, including BOMs, revision control, and serialized outputs for traceability. For <strong>server router internal wiring<\/strong> and <strong>data center switch wire harness<\/strong> applications, the combination of precision manufacturing and rigorous testing ensures that every cable harness meets the required specifications.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-15371\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/07\/\u7ebf\u675f\u52a0\u5de52.jpg\" alt=\"Cable Assembly\" width=\"1920\" height=\"960\" \/><\/p>\n<\/section>\n<section id=\"outcomes\">\n<h2>4. Outcomes: Signal Integrity, Space Savings, and Supply Chain Consolidation<\/h2>\n<p>The custom cable harnesses delivered by TPS Elektronik exceeded the customer&#8217;s performance targets while simplifying their supply chain and reducing assembly time.<\/p>\n<p><strong>Key Outcomes:<\/strong><\/p>\n<ul>\n<li><strong>Signal integrity:<\/strong> Internal cable assemblies maintained impedance control and signal integrity at 25 Gbps data rates, enabling the switch platform to meet its performance specifications<\/li>\n<li><strong>Space savings:<\/strong> The compact cable harness design freed up valuable PCB space for additional functionality<\/li>\n<li><strong>Reduced assembly complexity:<\/strong> Pre-assembled harnesses with labeling and strain relief reduced chassis assembly time by approximately 25% compared to manual point-to-point wiring<\/li>\n<li><strong>Supply chain consolidation:<\/strong> A single partner provided cable assembly, testing, and documentation, eliminating the need for multiple suppliers<\/li>\n<li><strong>Documented quality:<\/strong> 100% continuity testing and inspection reports provided traceable quality evidence for each production batch<\/li>\n<\/ul>\n<p><strong>Operational Benefits:<\/strong><\/p>\n<ul>\n<li><strong>Reduced field failures:<\/strong> Consistent manufacturing processes and rigorous testing eliminated cable-related field failures that had plagued previous platforms<\/li>\n<li><strong>Faster time-to-market:<\/strong> DFM feedback and rapid prototype turnaround accelerated the development cycle<\/li>\n<li><strong>Scalable production:<\/strong> The validated manufacturing process supported volume production without quality variation<\/li>\n<\/ul>\n<p>This case study demonstrates how TPS Elektronik combines expertise in <strong>custom cable assembly<\/strong>, precision manufacturing, and quality assurance to deliver integrated solutions for high-speed networking equipment. By providing a single accountable source for complex interconnect needs, TPS helps system integrators and procurement teams reduce supply chain complexity and accelerate time-to-market.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/cable-assembly\/\">Request a custom cable assembly RFQ \u2192<\/a><\/p>\n<\/section>\n<section id=\"tps-capabilities\">\n<h2>5. TPS Custom Cable Assembly Capabilities for Networking Equipment<\/h2>\n<p>TPS Elektronik&#8217;s <strong>custom cable assembly services<\/strong> for networking switches and routers combine precision manufacturing, engineering support, and comprehensive quality assurance in a single integrated workflow.<\/p>\n<p><strong>Manufacturing Capabilities:<\/strong><\/p>\n<ul>\n<li><strong>High-speed twinaxial cable assembly:<\/strong> Differential pair cables for data rates up to 25 Gbps and beyond<\/li>\n<li><strong>SFP\/QSFP cable assemblies:<\/strong> Custom length and connector configurations for networking applications<\/li>\n<li><strong>Breakout harnesses:<\/strong> QSFP to four SFP+ fan-out assemblies<\/li>\n<li><strong>Shielded cable assemblies:<\/strong> Foil and braid shielding for EMI control<\/li>\n<li><strong>RF\/coax cable assemblies:<\/strong> SMA, BNC, and TNC connectors for networking applications<\/li>\n<li><strong>Precision termination:<\/strong> Controlled crimping and soldering processes for reliable connections<\/li>\n<\/ul>\n<p><strong>Engineering Support:<\/strong><\/p>\n<ul>\n<li><strong>DFM feedback:<\/strong> Design optimization for manufacturability and reliability<\/li>\n<li><strong>Cable and connector selection:<\/strong> Guidance based on electrical, mechanical, and environmental requirements<\/li>\n<li><strong>Routing optimization:<\/strong> Cable routing paths designed to maintain signal integrity<\/li>\n<li><strong>Prototype development:<\/strong> Rapid turnaround for design validation<\/li>\n<\/ul>\n<p><strong>Quality and Testing:<\/strong><\/p>\n<ul>\n<li><strong>100% continuity testing:<\/strong> Every conductor in every assembly<\/li>\n<li><strong>Impedance verification:<\/strong> 100\u03a9 differential impedance for high-speed data<\/li>\n<li><strong>Dielectric withstand and insulation resistance testing:<\/strong> Per applicable standards<\/li>\n<li><strong>IPC\/WHMA-A-620 Class II\/III compliance:<\/strong> Workmanship standards<\/li>\n<li><strong>Documentation:<\/strong> BOMs, revision control, serialized outputs, and test reports<\/li>\n<\/ul>\n<p>TPS supports both prototype and production volumes, with quotes provided in 24\u201348 hours and prototypes available in 1\u20132 weeks.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/cable-assembly\/\">Get your custom cable assembly RFQ in 24\u201348 hours \u2192<\/a><\/p>\n<\/section>\n<section id=\"faq\">\n<h2>6. FAQ<\/h2>\n<div>\n<div>\n<h3>What types of cable assemblies does TPS manufacture for networking switches and routers?<\/h3>\n<div>\n<div>TPS manufactures high-speed internal cable harnesses for networking equipment, including differential pair assemblies, SFP\/QSFP cable assemblies, breakout harnesses (QSFP to four SFP+), and shielded cable assemblies. TPS also provides RF\/coax assemblies with SMA, BNC, and TNC connectors for networking applications.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What data rates can TPS cable assemblies support?<\/h3>\n<div>\n<div>TPS cable assemblies support data rates up to 25 Gbps per lane and beyond, with differential impedance control for high-speed signal transmission. SFP\/QSFP assemblies can support aggregate data rates of 100 Gbps and 200 Gbps for high-speed data center applications.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What testing does TPS perform on cable assemblies for networking equipment?<\/h3>\n<div>\n<div>TPS performs 100% continuity testing on every assembly, along with impedance verification, dielectric withstand testing, and inspection per IPC\/WHMA-A-620 standards. RF cable assemblies can be verified with VNA sweep and TDR testing. All test results are documented.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>Can TPS provide custom lengths and connector configurations for networking applications?<\/h3>\n<div>\n<div>Yes. TPS manufactures custom cable assemblies in specific lengths and with specific connector configurations to match chassis layouts and networking equipment requirements. DFM support is provided during the design phase.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>What standards does TPS follow for cable assembly manufacturing?<\/h3>\n<div>\n<div>TPS follows IPC\/WHMA-A-620 Class II\/III workmanship standards for cable and harness assemblies. TPS also references IEC 61196-1-111 for phase stability test methods and IEC 61169 for coaxial connector performance.<\/div>\n<\/div>\n<\/div>\n<div>\n<h3>How does TPS ensure traceability of cable assemblies?<\/h3>\n<div>\n<div>TPS provides serialized outputs, laser marking, shrink labels, and barcodes for traceability. Full documentation including BOMs, revision control, and test reports is provided with every order.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Ready to manufacture high-speed internal cable harnesses for your networking switches and routers?<\/strong><br \/>Contact TPS Elektronik for DFM feedback, prototype evaluation, and production support\u2014from custom cable assembly to integrated box build.<br \/><a style=\"color: #ffffff; font-weight: 600; text-decoration: underline;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/ems\/cable-assembly\/\">Request your custom cable assembly quote \u2192<\/a><\/p>\n<\/footer><\/article>\n\n<style id=\"wpforms-css-vars-4659-block-31119cd6-825e-4194-bfcd-70f48cdc5d04\">\n\t\t\t\t#wpforms-4659.wpforms-block-31119cd6-825e-4194-bfcd-70f48cdc5d04 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the internal cabling of switches and routers is not just about connecting point A to point B\u2014it is about maintaining signal integrity at data rates exceeding 25 Gbps while fitting into ever-shrinking chassis footprints. A single poorly routed or improperly terminated cable harness\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-provide-compact-and-high-speed-interconnects-for-networking-switches-and-routers-with-tps-custom-cable-assembly-services\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":16958,"template":"","class_list":["post-16710","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Provide Compact and High Speed Interconnects for Networking Switches and Routers with TPS Custom Cable Assembly Services? - TPS<\/title>\n<meta name=\"description\" content=\"Custom cable assembly services for networking switches and routers with high-speed differential pairs, SFP interfaces, and 100% continuity testing.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/how-to-provide-compact-and-high-speed-interconnects-for-networking-switches-and-routers-with-tps-custom-cable-assembly-services\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Provide Compact and High Speed Interconnects for Networking Switches and Routers with TPS Custom Cable Assembly Services? 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