Technical Cable Applications is a contract cable manufacturer specializing in the field of custom cable assemblies and wiring harnesses. With a huge selection of automated and manual tools to prepare outsourcing products, Technical Cable can build your custom designed parts and cables, and inspect the finished goods for perfection. Our engineers and technicians are highly qualified and trained, and we have experts for each part of the drawing, design, prototyping, manufacturing and testing processes that any full cable design and building project requires.
At Technical Cable Applications, the first and most important step of the cable manufacturing process is pre-planned design. Manufacturing cables and harness assemblies requires custom solutions. Each assembly production is different, and each cable project brings forth new and exciting engineering. We are constantly innovating and investing in new solutions and tools to speed up and improve our design and manufacturing processes. We also hire only the best engineers and technicians to draw new designs and prototype them, so that we can continually push the envelope and grow our manufacturing and custom wire capabilities each year.
Technical Cable Application's team works with highly qualified cable manufacturers. Together, they work to make sure that the services and parts needed are assembled and delivered perfectly. TCA performs manufacturing solutions quickly, and without losing sight of the customer’s need for custom services and high-quality results. We keep the parts and tools on hand for most typical cable styles and connectors so that we can get to work right away on bulk orders of pre-existing designs, while also keeping our innovative engineers on site to assist with every new project we take on and maintaining relationships with materials providers so that we can order anything additional needed for a project quickly.
Our design and R&D engineers are some of the best in the nation, and we pride ourselves on our ability to design and prototype excellent new concepts for cables and wires. Our drawing and modeling team will create a blueprint that will be built and prototyped until the cable or wire meets the requirements for the project, and ultimately help meet the goals that you have for your data transfer, power delivery, or Internet speed needs.
Once the cable designs are approved, TCA orders the parts needed to begin proper cable assembly production. Automation has been developed for aspects of contract cable and harness assembly like automated wire cutting, stripping, crimping, 3D printing, and injection molding. Much of the work is custom and hand made as well, by IPC certified and trained cable technicians when necessary. Our team of technicians are experienced and qualified, and always ensure that every wire and cable they touch is assembled properly and carefully.
At TCA, wire cutting is often the beginning of many projects if the design is already in place. This phase is mostly automated with our robotic despoiling and wire cutting machines to produce the correct lengths. Followed by stripping and adding custom connectors, the cable is stripped back to reveal its core so the next steps of assembly can be completed. This automation and the special machines that utilize it allows us to start with an extremely solid beginning for every cable and wire before further steps are completed.
With the cores exposed, custom connectors can be added. Doing this includes crimping and soldering the wire into the proper connections. Many manufacturing steps are automated, and those that cannot be automated are done by hand by skilled custom operators. We are continually improving our crimping and soldering processes by acquiring new tools and machines, including the Schleuniger 36SP Crimp Center that we started using in 2021. Using the best and most powerful machines for precise work means that quality assurance is involved in every step of our manufacturing processes.
After the crimping and soldering processes have been completed, the terminated wires are gathered up and crafted into the contract harnesses themselves. This step requires most of the manual wire. Each wire is fed through or bundled together, taped off and measured to make sure the dimensions match the manufacturer design specifications. TCA adds coverings, braiding, heat shrinkable tubing, transition boots, and tubing products as required.
When the cable manufacturing or custom wire harness is finished, thorough inspection is completed to all assemblies, to inspect the drawing for dimensions, continuity, and note compliance. Each step in the product inspection procedure is monitored and tracked. In the event of any failure to pass our strict tests for quality, we will immediately address and locate the issue, make it right, and ship quickly to ensure minimal delays. Any manufacturing failures are always fixed, the parts are retested, and moved to shipping when the manufacturing is approved.
Founded in 2002 and operating out of Auburn, WA in Washington state, Technical Cable Applications is a manufacturer for tens of thousands of completely custom contract cables, and many high quality wiring harnesses projects per month. We work with clients all over the United States in dozens of industries, including construction, telecommunications, aerospace, healthcare, industrial manufacturing and many more. If you have a large project requiring custom cables or a bulk order of high quality harnesses, we have you covered as your one-stop cable design and manufacturing expert. There's no need to work with multiple manufacturers all over the place when Technical Cable Applications can take care of the entire project on your behalf.
Whether you need high transmission ethernet cables to utilize your business' fiber Internet access, complex harnesses for huge construction projects that must be extremely durable to survive outside, or a custom coaxial cable solution to power your telecommunications company's expansion efforts, Technical Cable Applications is the trusted American cable manufacturer to turn to. Our facility is in the Pacific Northwest which is an excellent place to work, but we serve the whole country and can ship all over as you require it for your cable needs.
Call TCA today for any needs involving custom cables or bulk cable, wire and harness orders!
Call 253-289-5572
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2022 marks our 20 year anniversary and to celebrate we will be hosting our first annual (?) golf tournament this fall! We’re very excited about this and already have partners lined up to sponsor various holes, prizes and games. The tournament is open to all of our partners, suppliers and customers. We look forward to seeing you on the course!
First Annual Golf tournament (8)
I mentioned in a previous post that TCA had expanded both here in Auburn, WA as well as the Southwest. Formally, I’d like to introduce you to Jim Henderson who represents our Southwest business. Located just outside of Phoenix, AZ Jim comes with years of experience in structured cabling, wire harnesses and cable assemblies. Jim is on the ground in Arizona and available to visit your facility for consultation and to review your requirements. He comes fully supported with a strong engineering team behind him available to help with costing, tooling, first articles, work instruction creation and eventually getting your assemblies into full scale production. You can reach him immediately by calling our main line (253) 289-5572.
One day I may just up and open up a museum dedicated to TCA antiquities. Does anyone out there still have one of our original 2002 logo style hats? I can’t even begin to count how many variations of t-shirts, hats, pens, golfballs, catalogs, fliers or other paraphernalia we’ve had over 2 decades. As we get closer to getting back into trade show mode, it’s fun to review our old displays made eons ago. When our staff was less than 25% of what we are today, we were already pounding out more than 50,000 cat5e and cat6 network cables per month, all custom made to the inch.
We have custom display boards for all types of assemblies but what caught my eye today was the molded USB we created years ago. Using a common base USB A connector from a trusted manufacturer we were able to design an overmold that created protection, strain relief, and not one but THREE exit holes. This old display model may be showing some dust and age but the design is beautiful and what goes into it is still impressive to me. Multiple solder joints and splices lie under that tiny mold. I told you custom molds get me excited!
