Assembly to Wrap and Sintering . . . and Everything In Between
We cut the wire to the desired length on a wire-cutting machine. The wires are then stripped to expose the metal. Next, the wires are fitted with terminals or connector housings. Finally, the cables are assembled and clamped together according to the design specifications.
We offer a wide variety of coiling constructions. Our coil cords are available in axial, tangent, and performed tails. Coil cords can be designed with controlled retraction force.
Our extrusion process creates a protective and aesthetic coating on a bare wire. The bare wire is pulled through the center of a die to create a colored, insulated jacket. This process is high volume and creates a continuous and consistent profile. Our fluoropolymer extrusion line allows for the insulation of wires and cables with aerospace qualified polymers. Please select Materials for a list of materials we extrude.
We braid round and flat shields. Our shields stop electromagnetic interference, block external noise, resist abrasion, increase overall pull and cut-through strength, and protect from fire.
Insert molding enhances a cable assembly’s functionality, durability, and aesthetics. These enhancements are achieved by encasing areas of the cable assembly with plastics such as PVC, PP, TPEE, and TPR.
Overmolding allows for a strong bond between two different materials without the use of adhesives. We can overmold connectors, strain reliefs, grommets, yokes, and other applications.
Our in-house tooling department can match or custom build nearly any mold.
We create functional prototypes. A working prototype gives you certainty in the design of your project. We can help you develop your custom design. We have years of experience designing for a myriad of applications. We can source the necessary materials to develop and manufacture your product. We can do it all in our facilities.
We can robotically terminate wires with the use of our MTX machine. This automated process offers significant cost savings for high-volume products that do not require custom terminations and overmolding.
Shielding and Cabling
We have complete in-house capabilities to shield multiple insulated conductors. This allows us to enclose a common conductive layer. We use rigorous, proprietary tests to ensure quality in all of our cables.
We have four testing labs.
Our electrical lab features an EMI chamber. We can provide full pre-compliance electromagnetic compatibility and shielding effectiveness testing for prototypes, finished electrical sub-components, and full assemblies.
Our mechanical lab offers complete test and measurement.
Our signal integrity lab allows us to test electrical integrity and shielding effectiveness.
Our nanotechnology lab enables us to experiment with carbon nanotubes on non-metallic conductors and shields. Our testing has already paid dividends. We have identified and are now developing new processes for the use of carbon nanotubes in wire and cable manufacturing.
Our testing capabilities include flex life, stretch, torque, low noise, submersion, high-speed thermal mass flow leak, tensile and compression (pull test), OGP SmartScope 250 (Non-contact optical comparator), impulse/abrupt, MIL-C-17G (cable test), and AAMI/ANSI EC53-1995.
We have an accomplished tooling design and fabrication department. We can create nearly any mold for the wire and cable industry. Our engineered designs are created in a software program for optimum throughput. Each mold is designed for manufacturing ease. The mold is then made on our CNC machine guaranteeing precision measurement.
We can cut, strip, crimp, and terminate one or both ends of a wire. This automated process guarantees accuracy and saves time and labor.
Wrap and Sintering
We have insulation, dielectric, and shielding capabilities. Processing materials include PTFE, polyester, polyimide (Kapton & Oasis), metal foils, metalized polymer tapes, and unique conductive tapes.