Cable Manufacturers
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.
