Frequently Asked Questions

Our company's main profile is high-quality cable assembly and complex wire harness production. We offer full-service solutions in the field of industrial electronics, whether it's simple connector insertion or complex wiring of control units.

Yes, custom cable manufacturing is a core service for us. Our flexible machinery allows for specialized wire production processes, ensuring that products are made exactly according to the customer's specifications.

To ensure precision, we prepare wires using high-end Komax and Metzner cutting machines. These devices guarantee precise cutting and damage-free stripping during every cable manufacturing process.

For maximum contact safety, crimping is our most common procedure, but if the technology requires it, high-quality soldering is also part of our daily workflow. We apply strict quality control during both cable assembly and wire installation.

While assembly usually involves fitting individual cables with connectors, a wire harness is a complex system of several different wires and connectors bundled together into a single unit using ties, protective tubes, or heat-shrink tubing.

Crimping is the process where a metal crimp (terminal) is pressed onto the end of a stripped wire with high force. The goal is to compress the copper strands and the connector so tightly that neither air nor moisture can get between them – this is called a gastight or airtight connection.

To ensure the connection works flawlessly for years, we focus on the following:

• Professional tools: We do not use combination pliers or improper tools. Crimping is performed using precisely calibrated semi-automatic and fully automatic machines.
• Continuous quality control: We do not leave quality to chance. We regularly perform tests:
  • Pull-out force: We measure how much force would be required to pull the cable out of the connector (ensuring it will not loosen).
  • Cross-section analysis (microscopic inspection): From time to time, we cut test samples in half and examine them under a microscope to ensure the inner copper strands have merged perfectly with the metal terminal without any gaps.

During soldering, we use liquid tin (solder) to practically "fuse" the wire and the connector together. A good solder joint not only conducts electricity but also holds the components together with strong mechanical resistance.

For safe operation, we follow these rules:

• Spotless cleanliness: The solder will only adhere properly if the surfaces are clean. We use a special cleaning agent (flux) that removes invisible contamination and helps the solder spread evenly.
• Perfect temperature: This is the most critical point. If the soldering iron is too cold, the solder will not flow properly (this is called a "cold solder joint", which fails quickly). However, if it is too hot, the plastic insulation of the cable may melt or become damaged.
• Just the right amount of solder: In a good solder joint, the tin runs thin and shiny around the connection point. A large, bulky lump of solder often hides internal defects, while too little solder breaks easily.
• Immobility during cooling: Until the hot solder has cooled down and solidified, the cable must not be moved for even a second. If it moves, microscopic cracks invisible to the naked eye will form, leading to intermittent contact issues later on.

For us, cable assembly involves two main tasks: first, the precision mounting of various connectors onto cables, and second, the professional wiring and connection of the finished cables into electrical devices, machinery, or motors.
To ensure the assembly is durable and that machines do not break down later due to contact failure, we pay special attention to the following:

1. Mounting connectors onto the cable

• Damage-free stripping: The outer plastic insulation is removed in a way that prevents even the smallest part of the inner copper strands from being damaged.
• Strong and durable fastening: Connectors are secured using special pressing tools (crimping) or by soldering. This ensures the connection does not loosen and conducts electricity perfectly.
• Protection against environmental influences: With heat-shrink tubing and strain reliefs, we ensure the cable does not break at the base of the connector and that neither moisture nor dust can penetrate.

2. Wiring into motors and electrical devices

• Strict diagram compliance: All connections are made strictly according to wiring diagrams, schematics, and standard color codes, completely eliminating errors.
• Secure screwing: For internal motor connections, we tighten screws with a measurable force (torque). This prevents the screws from loosening due to machine vibration, while also ensuring they do not snap from overtightening.
• Organized internal routing: Cables are routed aesthetically and bundled inside the machine so they do not touch moving or hot components.

Inspection: At the end of the process, every single cable and connection is instrumentally tested (short-circuit and continuity test), ensuring that only guaranteed, functional products or equipment reach you.

Of course. We have extensive experience in special cable manufacturing, whether it involves unique insulation, shielded systems, or wires exposed to extreme environmental stress.

No, our capacity allows for the efficient execution of large-scale wire production as well. Thanks to our automated processes, we can adjust the volume of cable manufacturing to meet the customer's needs, from prototypes to batches of several thousand units.

By utilizing our quality cable assembly services and modern machinery, our customers can save significant investment costs. We provide the expertise, raw material management, and a guaranteed quality end-product.

Every single wire harness and assembled cable undergoes electrical testing and visual inspection. To ensure a high-quality result, crimp force and connection integrity are regularly checked with calibrated measuring instruments.

For a custom cable manufacturing quote, we need the technical drawing, the Bill of Materials (BOM list), and the planned quantity. If an exact plan is not available, our engineers can also help with the technical design of the wire assembly.