From consulting to production
Pioneering technologies & individual solutions
Our production processes
Standard cable assembly
Cutting to length
Series production begins with cutting single wires, sheathed cables, corrugated tubes, heat-shrink tubes and insulating sleeves to length. For this purpose, cutting machines and fixtures suited to the respective application are used. This also ensures a straight cut at the crest of the corrugation when cutting corrugated tubes to length, which prevents the internal cables from chafing and wearing on the outer cut edge.
Stripping the sheath
For further processing, sheathed cables are stripped using machines suitable for the respective cable type. The sheath enclosing the individual wires is removed at the ends so that the individual cores are exposed for further processing. Depending on the application, this step is carried out automatically together with cutting to length.
Crimping
To populate the connectors, the single wires or the exposed cores of the sheathed cable are first crimped with the appropriate contacts. Crimping machines with integrated crimp force monitoring are used to ensure a proper connection. Depending on the application, the wire is fully automatically stripped, fitted with a single-wire seal and then crimped.
Soldering
Similar to crimping, soldering offers a further method of connecting conductor and contact or of producing splices. For soldered splices or butt connectors, a suitable adhesive-lined heat-shrink tube is also applied to ensure sealing and electrical insulation.
Potting
To create a watertight connection even for connectors to which no seals can be fitted, these are potted with a 2-component polyurethane casting resin. Splices can also be potted instead of using heat-shrink tube, either on their own or together with the connector. This ensures both sealing and electrical insulation.
Marking
The cables can also be marked for clear identification. A special white heat-shrink tube is printed using a thermal transfer printer and then positioned at the cable ends. This allows single wires with a diameter of 1.5 mm up to sheathed cables with a diameter of up to 50 mm to be marked.
For larger quantities, we also offer direct printing on cables. Here, the single wires are printed using the inkjet printing process.
Labelling
For quick identification, products can be provided with labels showing the quantity, item description and item number. The item number is also shown as a barcode (Code 39). The labels are attached either directly to the product or to the zip-lock bag.
