Custom Subsea Connector and Cable Assembly Solutions
Shanghai Kabel Intelligence Technology Co., Ltd. specialises in the design, engineering and manufacture of custom subsea connectors and OEM underwater cable assemblies for the demanding marine, offshore, ROV, AUV and oceanographic industries. Our team combines decades of underwater connector engineering experience with state-of-the-art manufacturing capabilities to deliver connector and cable solutions that meet your exact technical specifications.
Whether you need a modified version of an existing standard connector, a completely bespoke subsea interconnect system, or a fully integrated cable assembly with custom terminations, Shanghai Kabel has the engineering expertise and production capacity to deliver. We have supplied custom subsea connectivity solutions to ROV manufacturers, offshore operators, defence contractors, research institutions and subsea equipment OEMs worldwide.
Our Custom Capabilities
Custom Connector Design and Modification
We can modify any of our standard connector series — Micro Circular, Circular, Low Profile, Ethernet, Optical Fiber & Power, High-Power, Coax, Metal Shell, RMG and more — to meet your specific requirements. Modifications include:
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Custom shell materials: anodized aluminium, stainless steel 316, titanium, or customer-specified alloys
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Custom contact arrangements, pin counts, and mixed-contact configurations (power+signal+coax+fiber)
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Special plating options for contacts and shells for enhanced conductivity or corrosion resistance
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Customer-specified O-ring materials for extreme temperature or chemical exposure environments
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Custom bulkhead thread lengths, flange patterns, and mounting configurations
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Unique keying or polarisation options to prevent mis-mating in multi-connector systems
Custom Cable Assembly Manufacturing
Our cable assembly facility produces subsea cable harnesses from 1 metre to 1,000+ metres with a wide range of cable types:
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Single-core and multi-core power cables (various AWG sizes and voltage ratings)
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Signal cables: twisted pairs, triaxial, multi-conductor shielded/unshielded
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Coaxial cables: 50 ohm, 75 ohm, RG59, RG174, RG213 and custom specifications
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Ethernet cables: Cat5e, Cat6, Cat6a, Cat7 for underwater data transmission
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Fibre optic cables: single-mode, multi-mode, hybrid fibre+power combinations
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Hybrid cables: any combination of power, signal, coax, ethernet and fibre in a single jacket
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Neutrally buoyant tether cables for ROV and AUV applications
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Armoured cables with Kevlar, polyester or Dyneema strength member reinforcement
Connector Termination and Over-Moulding
All our custom cable assemblies are terminated with precision using:
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Direct over-moulding to connector bodies for strain relief and waterproof sealing
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Solder cup, crimp and PCB termination methods available
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Potting with polyurethane or epoxy for void-free sealing
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PUR, TPU, Neoprene, PVC and specialised jacket materials
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Connector-cable transition moulding with bend restrictors and strain relief boots
Testing and Quality Assurance
Every custom assembly undergoes rigorous testing before shipment:
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Hydrostatic pressure testing up to 10,000 psi (700 bar) with full certification
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Electrical continuity and insulation resistance testing
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High-potential (hipot) dielectric strength testing
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Visual inspection, dimensional verification and connector mating cycle testing
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Cable pull-out force testing per applicable standards
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Optional: temperature cycling, flex testing, chemical exposure testing
Custom Design Process
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Requirement Analysis — Our engineering team reviews your technical specifications, drawings, and application requirements
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Concept Design — We create preliminary designs, 3D models, and technical proposals for your approval
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Prototyping — Samples are manufactured and tested to validate form, fit, and function
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Production — Full manufacturing with our quality management system and process controls
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Testing and Certification — Complete electrical and pressure testing with certificates of conformance
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Delivery and Support — Global shipping with ongoing technical support for your project
Applications
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Custom ROV and AUV tether cable assemblies with specific conductor configurations
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OEM subsea sensor and instrument connector interfaces for oceanographic equipment
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Offshore platform subsea control umbilical connectors and cable assemblies
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Defence and naval underwater system connector solutions with MIL-spec requirements
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Marine renewable energy cable interconnection systems for tidal and wave power
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Custom underwater camera, lighting and video system cable assemblies
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Subsea battery pack connectors and charging cable solutions for AUV fleets
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Specialised underwater connector solutions for deep-sea research and exploration
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Replacement and upgrade connectors for existing subsea systems no longer in production
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Custom penetrator and feed-through connectors for pressure vessel applications
Customization Options
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Full OEM design and manufacturing service from concept to production
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Custom connector body materials, contact materials, and plating options
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Customer-specified cable types, lengths, conductor configurations, and jacket materials
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Direct over-moulding to connector bodies for complete, sealed assemblies
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Custom packaging, labelling, and documentation per customer requirements
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Certified pressure testing to specified depth ratings with full test reports
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ISO-compliant manufacturing with traceability and quality documentation
Frequently Asked Questions
What is the minimum order quantity for custom connectors?
We accept custom connector orders starting from small prototype quantities (as few as 2-5 pieces) through to volume production runs of hundreds or thousands of units. Contact our sales team with your requirements for a specific quotation.
How long does a custom connector project typically take?
Typical lead times range from 2-6 weeks for modified standard connectors to 8-12 weeks for fully custom designs, depending on complexity, material availability, and testing requirements. Rush orders can be accommodated for urgent projects.
Can you reverse-engineer an existing connector?
Yes. Our engineering team can reverse-engineer existing connectors, including those that are obsolete, discontinued, or from other manufacturers, and produce compatible or improved replacements. We can work from physical samples, drawings, or 3D scan data.
Do you provide CAD models and drawings for custom designs?
Yes. We provide 2D engineering drawings and 3D STEP/IGES models for all custom designs as part of the design and approval process.
What quality certifications does your manufacturing facility hold?
Our manufacturing facility operates under a quality management system that can provide ISO-compliant documentation, material certifications, test reports, and certificates of conformance for all custom products.
Contact Our Custom Engineering Team
To discuss your custom subsea connector or cable assembly requirements, contact our engineering team:
Email: sales@rovcable.com
Website: www.rovconnector.com | www.rovcable.com
Shanghai Kabel Intelligence Technology Co., Ltd.
No.100 Yezhuang Road, Fengxian District, Shanghai, China 201415
