Our Wire Harness Manufacturing Process
Located in northeast Ohio, our state-of-the-art facility is fully equipped to handle high and low volume orders of custom cable and harness assemblies of any size. Our automated and semi-automated equipment allows us to process UL and non-UL types of wire with various insulations and cable from 4/0 to 32 gauge.
Depending on the wire or cable being processed, there are several options for cut and strip machines, dereeling stations, and coiling systems to be employed. Cutting and stripping can be completed with either “V” style, die blades, or rotary cutters to ensure the best possible strip.
Dereeling systems allow for 10″ reels at 2 pounds all the way up to four-foot reels weighing in at several hundred pounds. An attachment to each of our wire processing machines, automated coiling systems provide options when running lengths longer than four to five feet. For short runs of very large gauge cable 2AWG – 4/0 and heavy reels, MJM has a custom-built system to measure and payoff long lengths of cable into individual coils.
Removing insulation from conductors may sound simple, however there exists a science around proper methods. At MJM, we utilize mechanical “V” blades, custom die blades, thermal and chemical process, as well as dual-axis laser systems.
Each method is determined by volume, speed, wire size, jacket material, end product application, and total cost.
Typically, a mechanical means of wire stripping is most cost effictive and is used in high-volume applications. With the correct blades, both the strip quality and output can be effectively maintained well within the requirements laid out in the IPC-620 workmanship standard.
For those requiring Class III workmanship, our laser wire stripping machine offers a practical solution for accurately stripping small diameter wires and unsymmetrical shielded cables. This highly precise process eliminates the risk of mechanical damage to internal insulation materials and the conductor while stripping ends, along with performing cross cuts, windows, and patterns, depending on your requirements.
Our laser wire stripper is a computer-controlled machine that uses a laser to burn off the insulation of the wire. Although it takes more time to process, resulting in a slightly higher cost, this precise wire harness manufacturing process allows us to offer repeatable results when processing multiple wires and cables simultaneously.
The attachment of terminals and connectors can be done with several methods. At MJM, these methods include crimping, traditional soldering methods, reflow solder technology and ultrasonic welding. While crimping is used in 80% of all applications, soldering can provide a permanent connection that acts like a “glue” that holds electrical parts together.
A final method is Ultrasonic Welding for the splicing of wires and/or cable assemblies. This method uses high-frequency vibrations, removing the need for mechanical crimp connections and offers very fast and efficient results with repeatable welds. The welds are also more durable (rugged) than other traditional methods of joining which improves product reliability.
Cable Assemblies for Any Industry
As a leading contract manufacturer, we strive to deliver reliable products backed by exceptional customer service to clients in any industry. Some of the industries we work with include:
- Defense and military
- Consumer products
- Industrial automation
- Medical equipment
- Mass transit
- Water equipment
- Commercial off-road
- Heavy equipment
- Test and measurement
A Leading Manufacturer of Custom Cable Assemblies and More
In addition to wire harnesses and cable assemblies, we provide a full range of services to compliment contract manufacturing at MJM. Our services include:
Looking for a Dependable Custom Wire Harness Manufacturer? Choose MJM Industries
Searching for a reliable and experienced custom wire harness manufacturer? MJM Industries is fully committed to quality assurance and providing our customers with high-quality cable assemblies. We are compliant with a variety of U.S. and international standards including:
- ISO 9001:2015 certified
- Underwriters Laboratories
- IPC/WHMA-A-620 and IPC-A-610 manufacturing workmanship standards
- ITAR compliant and Registered with the State Department
- Compliant with the Securities Exchange Commission’s Conflict Minerals Rule
- RoHS and WEEE Compliant
Contact the team at MJM Industries today for custom-made cable assemblies and wire harnesses. We are ready to work with you!