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Custom High-Voltage Cable Assemblies

High-Voltage Interconnect for Mission-Critical Systems

Caton designs and manufactures custom high-voltage cable assemblies and connectors from 1 kV to 250 kV for defense, semiconductor, aerospace, medical, and scientific systems — where corona-free performance, dielectric stability, and engineering accountability determine whether the system meets specification. Family-owned, US-manufactured, AS9100 / ISO 9001 / ITAR-registered. Engineering-led since 1973.

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Markets We Serve
Defense
High-voltage interconnect for missile defense, directed energy, hypersonics, and space-based defense. ITAR-registered, AS9100, and engineering-led on programs that cannot be serviced mid-mission.
Semiconductor
Precision HV interconnects, vacuum feedthroughs, and corona-free assemblies for semiconductor capital equipment. PEEK and FEP materials, partial discharge below 5 pC at 50 kV DC.
Aerospace
High-voltage interconnect qualified for commercial and military aerospace platforms. Altitude testing to 70,000 ft. Configuration control and obsolescence management across multi-decade program lifecycles.
Medical
Custom HV interconnect for medical capital equipment — diagnostic imaging, radiation therapy, sterilization, electrosurgery, and neuromodulation. Specialty supplier built for low-volume, high-complexity programs.
Scientific
Custom high-voltage assemblies for particle accelerators, research instruments, and high-energy physics platforms requiring HV engineering not available from catalog suppliers.
Industry leaders who specify Caton interconnect
Lockheed Martin Raytheon Applied Materials Honeywell
Why Engineers Choose Caton

Engineering-led. Accountable. Focused exclusively on high-voltage interconnect.

50+
Years engineering custom high-voltage cable assemblies, connectors, and wire — family-owned, same engineering team, US-manufactured.
Your design engineer talks to our design engineer. The answer comes from the person who can change the design, not from an account manager who has to check with engineering and call you back.
01
High-voltage design, in-house
Custom cable and connector design from 1 kV to 250 kV. Finite element analysis using Electro V10.2 for electric field optimization, corona mitigation, and dielectric stress analysis.
02
Test capability on-site
Corona inception and extinction, partial discharge, hi-pot, insulation resistance, dielectric withstand, and thermal cycling — all in-house. Altitude testing to 70,000 ft in our Tenney chamber.
03
In-house overmolding and manufacturing
Overmolded HV terminations engineered for the application, not adapted from commercial parts. Manufacturing engineers work at benches on the production floor, alongside the test stations and the build.
04
Configuration control across the program lifecycle
AS9100 / ISO 9001 / ITAR-registered. Locked configurations, controlled change management, and same-team engineering since 1973 mean the assembly qualified at design release stays available through the program lifecycle.
Find the Right Assembly for Your System

High-Voltage Cable Assemblies and Interconnect Solutions

Whether you need a proven standard platform or a fully engineered custom solution, Caton can help you select, specify, and qualify the right assembly for your system.

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Custom High-Voltage Cable Assemblies
For systems where standard platforms cannot meet your electrical, mechanical, or environmental requirements. Engineered insulation architecture, controlled termination geometry, and a design process that accounts for how the assembly will perform in your actual operating conditions — not just on paper.
1 kV to 200 kV+Custom ConfigurationsAerospace & Defense
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Standard High-Voltage Cable Assembly Platforms
Pre-engineered connector platforms with defined voltage classes and conductor configurations. A faster path to qualification on designs with decades of field performance behind them. Available in four series — each optimized for specific voltage and application requirements.
14 Series16 Series17 Series19 Series
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High-Voltage Wire
Rated 10 kV to 80 kV DC. Silicone insulation. Available in 22–8 AWG conductor sizes. Standard designs available from inventory, with custom configurations supported for applications requiring specific insulation systems or conductor specifications.
10–80 kV DC22–8 AWGSilicone Insulation
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Not sure which assembly fits your system?
Most engineers find the right platform in a single conversation with our team.
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Our Engineering Process

How We Engineer High-Voltage Performance

Reliable high-voltage cable assembly performance requires coordinated control across five critical disciplines. Most field failures trace back to a gap in one of them.

01
Insulation System Design
Material selection driven by voltage class, temperature rating, altitude, and exposure. Architecture validated across the full interconnect — not just the cable run.
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02
Electric Field Control
Molded geometry eliminates field concentration at interfaces. Tapered mating surfaces maintain a continuous dielectric path at every connection point.
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03
Termination Engineering
Controlled geometry at every termination point. Overmolded structures designed for long-term dielectric integrity under sustained voltage stress.
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04
Process-Controlled Manufacturing
AS9100-controlled build processes with configuration control and full material traceability from prototype through production.
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05
Electrical Test & Validation
Hi-pot and dielectric withstand testing on every assembly. In-house corona testing. FAI per AS9102. Full traceability of test results.
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Engineering Accountability

When High-Voltage Cable Assemblies Fail

Most high-voltage assembly failures are preventable. They trace back to engineering and manufacturing decisions made early in the design process — before anyone realized a problem was being built in.

 The Problem
Corona & Partial Discharge
Field stress exceeds dielectric strength at air gaps in the connector interface, degrading insulation over time — often without visible warning until the assembly fails.
How Caton Prevents It
Molded geometry and tapered mating interfaces eliminate air gaps and create a continuous dielectric path at every connection point. Assemblies are corona tested in-house before shipment.
 The Problem
Insulation Breakdown
Insulation selected for convenience rather than engineered for the application fails under real conditions — temperature extremes, altitude, or sustained voltage stress.
How Caton Prevents It
Insulation systems are selected and validated against the full operating environment — voltage class, temperature range, altitude, and chemical exposure — before the design is released.
 The Problem
Termination Failures
Poor termination geometry creates field concentration points that accelerate dielectric degradation at the most electrically stressed location in the assembly.
How Caton Prevents It
Every termination is engineered as part of the complete electrical system — controlled geometry, overmolded structures, and design validation before production release.
 The Problem
Inconsistent Production
An assembly that passes first article qualification may not perform the same way months into production without tightly controlled processes and material traceability.
How Caton Prevents It
AS9100 build processes, full material traceability, and configuration control ensure that production assemblies perform the same way the qualified article did — every time.

Talk to engineering about your program

New platform development, qualification, sustainment, or obsolescence recovery on fielded systems — the conversation starts at the engineering bench. Your design engineer talks to our design engineer.

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