Cable Assemblies & Wire Harnesses

All cable and wire harness assembly manufacturing is undertaken in our facility located in Garden Grove, California. Our facility is compliant with AS9100 and certified to ISO 9001:2008 quality standards. In order to streamline our processes and provide the most cost-effective, high-quality manufacturing solutions and products, our management and manufacturing teams practice continuous improvement processes such as Lean Manufacturing and other methods. The widespread use of workplace organization methodologies such as 5S, Kaizen events, and other derivative tools like TOC (Theory of Constraints) has enabled us to develop remarkable efficiency in our production process.

To ensure all our products perform reliably under extreme field conditions, every product is manufactured using detailed planning and quality assurance methods. Augmenting our facilities is a select staff trained in the Acceptability of Electronic Assemblies (IPC A 610D) and the Requirements and Acceptance for Cable and Wire Harness Assemblies (IPC WHMA A 620), as well J-STD-001 soldering. We are certified in these standards, and have in-house certified trainers and continuous training programs to ensure that all employees have the highest competency.

El-Com’s extensive manufacturing capabilities allow us to provide complete and expert solutions for your interconnect needs. We are specialists in producing high-performance cable assemblies, wiring harnesses, and interconnect systems that are built to function reliably under even the harshest conditions. These solutions range in complexity from simple, straight assemblies to sophisticated, high-density harnesses and circuitry.

Our cable assembly facilities.

Interconnect Solutions

  • Wire Assembly: From the simplest piece of cut and stripped wire to wire assemblies with hundreds of discrete points, El-Com has the experience, proven processes, and talented employees to build crimped or soldered wire assemblies efficiently and precisely.
  • Cable Assembly: Using round, shielded, flat, coax cable, and other derivatives, El-Com can produce cable assemblies for power, control, communication, and data transfer. We specialize in soldered, crimped, and mass terminations.
  • Special Processing (Potting/Molding): El-Com staff have years of experience in special processes like heat dissipating materials, epoxy potting and coatings, overmolding, and low/no out-gassing materials.
  • Wire Harnesses: El-Com’s complete wire harnesses are built on custom harness fixtures to ensure precise fit and routing of all bends and bundles. We offer several options for wire harnesses, including all power and control circuits, fully terminated ends using connectors, lugs, terminal blocks, etc., and sensors, motors, fans, or any required electro-mechanical components.
  • Cable Harnesses: Harnessing of multiple cable assemblies achieves a one-step “drop in” harness during system-level assembly. El-Com can bundle all power, video, communication, and control cables on a custom harness board to ensure every connection point is labeled, located, and oriented properly.
Our automated cable assembly testing system.

Our manufacturing processes include:

 
  • EMI shielding, protective covering
  • Cable jacketing
  • Cable looming and weaving
  • Conformal coating
  • High reliability soldering and assembly
  • Hot and cold molding
  • Hot stamp marking
  • Potting
  • Thermoplastic injection molding
Our over molding equipment.
Our laser stripping equipment.