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Technical Cable Applications Blog

Cable Overmolding, Custom Cable Assemblies, Custom USB Cables, Ethernet Patch Cables

Custom USB Cables and Other Relics

Jun 17, 2022 by Dustin Twiggs 0 Comments

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 build 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 innovation 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!

 

 

 

Power Cable

Large Gauge Locomotive Cable

Jun 16, 2022 by Dustin Twiggs 0 Comments

In 20 years of business there have been countless experiences that excited me, and anyone who’s worked with me has heard me say “we sell solutions”. I feel strongly about that because we do. Many businesses sell cable assemblies and wire harnesses but our aim is to create additional value in providing those cable assemblies.  Often times the additional value our customers come to us for is looking for ways to manufacture an assembly more cost effectively or help improve a failing product to increase the integrity of the assembly in it’s specific application.  These days the number one value we hear of course is “lead time reduction”.  With supply chain issues running amok across all industries we have bolstered capacity across the board to ensure that our lead times are equal to pre-pandemic levels.  When it comes to cable assemblies there are always three immediate applications that excite me:

  • Molded assemblies. Anytime we get to mold something new there is a fun creative journey involved.
  • Large complex wire harnesses. When an assembly starts to reach 200+ points of inspection, harness boards, and hours of assembly time you really take a moment to appreciate both the engineering involved as well as the skillset of the technicians actually creating the final assembly
  • Large gauge wire assemblies.  Everything about it is big. Big spools, big connectors, BIG crimpers!

One specific application where we are seeing growth due to time constraints is in the very large gauge power cable.  Take for example something like AWC’s DLO-4/0 wire.  Tinned copper, 405A rating, 551 strands, and a whopping OD of nearly a full inch.  Pair that with the Panduit Pan-Lug LCA4/0-38-X 4/0 Lug and you have a whopper of an assembly most of our customers are not equipped to properly crimp.   Luckily, we are.  One such tool is the CT-3001/CCP Li+ Cut / Crimp / Punch tool.   It simply blows my mind that a tool weighing in at only 7.1lbs is equipped with a staggering 6.7 ton crimp capacity..

 

Business

2022 Company Updates

Jun 1, 2022 by Dustin Twiggs 0 Comments

Custom Cable Manufacturers Auburn, WA

As the world returns to some level of post-pandemic normalcy, I’d like to reflect upon the past two years of accomplishments at TCA.  2022 marks our 20 year anniversary as a company and yet we continue to maintain that “start-up” level of excitement and energy around the office. All of the sudden opportunities to gather in group settings, meet with customers face to face, travel, and attend trade shows again are popping up daily and what was old is new again.  The pandemic no doubt created new challenges and hurdles for every individual, company, school, and organization in the world, but I’m extremely grateful for how blessed we have been throughout the experience. In the past two years, TCA has:

  • Expanded real estate by 50%. Taking on new warehousing space for inventory management, production process development, and administrative offices.
  • Expanded our domestic molding capabilities by 50% with additional molding equipment and new dies.
  • Vastly expanded wire cut, crimp, strip, and tin capacity by utilizing Schleunigers automated crimp centers.
  • Began the journey of ISO certification, and achieved that certification the same year.
  • Launched our new website
  • Expanded our sales office into the southwest
  • Grew our staff by nearly double, with over 80 folks in our family here at TCA now.
  • Implemented a fantastic digital work instruction system with many custom modifications thanks to our partners at Scout Systems.
  • Implemented a new MRP system to further improve our efficiencies in inventory management, purchasing, and production work flow.

I am sure I am forgetting a lot, but I’m even more excited about the future.  We are once again looking at visiting trade shows, travelling to customer sites, spending more time together as co-workers at company BBQ’s, celebrating birthdays, and planning our first annual golf tournament.

So thank you to all of our amazing customers and suppliers that have worked together through these past 2 years to create such a fantastic foundation for the future.

power cables
Technical Cable Blog

UL Certified Cable Manufacturer

Dec 1, 2021 by Ward Dutton 0 Comments

Technical Cable Applications is a UL certified cable assembler.

The UL mark signifies that a product meets a stringent set of standards for both safety and quality. UL has developed guidelines and procedures to evaluate and certify millions of electronic and electrical components. UL certified components must be tested to meet certain requirements to mitigate risk factors such as fire and electrical shock.

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Technical Cable Blog

Battery Cable Assemblies

Nov 5, 2021 by Ward Dutton 0 Comments , , , , , , ,

The battery is a key component in powering our new generation of automobiles. It is an essential to start fuel powered vehicles, heavy equipment, fleet trucks, boats, and generators.  Batteries are used as a power source in RVs, campers, motor homes, golf carts and other off grid applications and used to store energy from solar and wind turbines.  One thing common to all this equipment is the need for battery cables. They make the connection from the battery to other components, and they must be reliable. Technical Cable Applications manufactures high quality battery cable assemblies for all these applications. 

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Custom Cable Manufacturers Auburn, WA
Technical Cable Blog

Cable Assemblies for Cryptocurrency Mining

Aug 25, 2021 by Ward Dutton 0 Comments

Cryptocurrency mining operations use various types of equipment to produce depending on the type of currency desired.  The many types of currencies like Bitcoin, Ethereum, Cash, Litecoin and HNT (Helium) require GPU, ASIC’s or HNT hardware devices. The most profitable undertakings are often located in high-speed data centers. Operations large and small all have one thing in common.  The need for cable assemblies to function.

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Cable Assembly
Technical Cable Blog

Onshore Versus Offshore Manufacturing

Jul 16, 2021 by Ward Dutton 0 Comments

There are a number of reasons you may have your assemblies built onshore.  You may also be thinking about bringing product back onshore in today’s market, but there can still be good reason to consider offshoring your assemblies. Here we will explore onshore versus offshore manufacturing of cable assembles. Technical Cable Applications can support both your onshore and offshore production requirements.

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