Cut and Prepared Wire Capabilities
Preparing a wire correctly is an important part of the finished electrical connection. Cut length, strip length, conductor condition and the quality of the termination all need to be controlled so that the prepared wire can be integrated efficiently into the next stage of manufacture.
Connect-2 Technology has invested in automated wire and cable processing equipment to support accurate and repeatable production across both straightforward and more involved wire preparation requirements. Our equipment includes technology from established manufacturers including Komax, Schleuniger and Kodera, supported by an extensive range of crimp and terminal tooling.
Our cut and prepared wire capabilities include:
- Precision wire cutting to customer-specified lengths
- Automated stripping of single-core and multicore cables
- Tinned ends, including hot-dip and precision tinning
- Crimp terminations using insulated and uninsulated terminals, including ring, fork, spade and bullet terminals
- Wire-to-wire and wire-to-board crimp assemblies
- Preparation of flexible copper braid, earth straps and power connections
- Wire identification using labels, markers and tags
- Cutting and preparation of sleeving and heat-shrink materials where required
Our automated wire-cutting equipment supports a broad range of wire and cable types. Connect-2 currently operates eight automated wire-cutting machines for the processing of single-core wire, copper braid, multicore cable and sleeving. Published equipment capability includes single-core wires from 0.03 mm² to 10 mm², with additional hydraulic cutting capability for substantially larger conductors.
If your requirement sits outside a standard wire-processing specification, speak to our engineering team. We can review the wire, terminal, connector, drawing or sample and discuss the most appropriate production route.
Crimped and Terminated Wires
Connect-2 holds a wide range of automatic and specialist crimp tooling, enabling us to support terminals and components from many leading manufacturers. Our equipment includes mini applicators, automatic presses, tooling for pre-insulated terminals and heavy-duty pneumatic and hydraulic crimping equipment.
This gives us the flexibility to manufacture prepared wires using a wide variety of terminal types and conductor sizes.
Terminations are produced to customer drawings, component-manufacturer requirements and agreed process specifications. Controlled tooling and inspection help support consistent crimp quality, mechanical retention and correct fit within the specified connector housing, terminal block or assembly.
Where additional testing or inspection is specified, this can be incorporated into the manufacturing process to suit the application and customer requirements.
Tinned Wire and Prepared Conductor Ends
Where a crimped termination is not required, Connect-2 can also supply prepared wires with tinned conductor ends.
Tinning can help prepare stranded conductors for particular assembly or termination processes and can be carried out according to the requirements of the finished application. We offer both hot-dip and precision tinning as part of our wire preparation capability.
The required cut length, strip length and tinned section can be defined as part of the customer specification, helping ensure wires arrive ready for use in the next stage of production.
Flexible Production for Prototype, Batch and Repeat Requirements
Prepared wire requirements vary considerably between customers. A development project may initially need a relatively small quantity, while an established production line may require regular repeat batches of the same wires.
Connect-2 has manufacturing capability designed to support this variation. Our production model can accommodate small single batches through to larger-volume repeat production, depending on the product and specification.
For customers with ongoing requirements, supply arrangements can also be tailored around the way your production operates. The wider Connect-2 service includes scheduled deliveries, multiple delivery drops, Kanban arrangements, buffer stocks for agreed key materials and JIT supply options.
This can be particularly useful where prepared wires are consumed regularly as part of an assembly process and need to be available without unnecessarily increasing your own stockholding.
Wire Identification and Production-Ready Supply
Where identification forms part of the specification, Connect-2 can supply cables and wires with labels, markers and tags to help identify individual wires during assembly, installation or servicing.
For repeat-production requirements, this means prepared wires can arrive in a format that helps reduce additional handling before they are used on your production line.
Identification can be incorporated as part of the wire preparation process, helping reduce additional handling before assembly.
Reliability Through Process Control
Consistency is particularly important with prepared wires because relatively small variations in stripping or termination can affect the next stage of assembly.
Connect-2 Technology operates an ISO 9001:2015 certified quality management system and has an IPC/WHMA-A-620 trained workforce. IPC/WHMA-A-620 is widely recognised within the cable and wire harness industry as a workmanship standard covering areas including cable and wire preparation, crimping and soldered connections.
We use controlled manufacturing processes, appropriate tooling and inspection to support repeatable production from one batch to the next.
The exact manufacturing and inspection process depends on the product and the customer's requirements. By establishing the specification at the outset, we can manufacture prepared wires around the dimensions, components, workmanship requirements and verification appropriate to the finished application.
A UK Manufacturer for Cut and Prepared Wire Requirements
Connect-2 Technology manufactures cable and wire products from our facility in Marske-by-the-Sea, Teesside.
As well as cut and prepared wires, our wider in-house capabilities include custom cable assemblies, wiring harnesses, electronic box build, fibre-optic cable assemblies, inspection and bespoke testing. As part of Cleveland Technologies Group, we can also support requirements involving UK-manufactured bare and assembled printed circuit boards through our sister company, Cleveland Circuits.
This broader capability can be useful for manufacturers looking to consolidate elements of their electrical and electronic supply chain, while customers who simply need prepared wires can continue to source them as an individual service.
Whether your requirement is for a straightforward cut-and-stripped wire, a crimped or tinned lead, an earth strap, a repeat production batch or prepared wires forming part of a larger assembly, our team can discuss the specification and production approach with you.