Cable Assembly & Wire Harness Solutions

At CAI, we design and manufacture wire harnesses, specialist cables and wiring looms for a wide range of industrial, commercial and domestic applications.

We combine over 40 years of experience in this highly specialist field with the latest technology in cable preparation and assembly, to make quality products built to last.

All of our manufacturing is done in the UK from our Cheshire facilities, where we take pride in delivering products that ensure exceptional reliability, performance, and durability, as expected and demanded by our customers worldwide.

We offer a limitless range of services & cable products for all industries, including:

• Customised Cable Assembly, Looms & Harnesses
• Mil-Spec & Aerospace Harnesses
• Box Build & Control Panel Wiring
• Specialist Industrial Application Harness Solutions
• Automotive Harnesses
• Sensor/Actuator Cable Assembly
• Audiovisual Cable Assembly
• Vehicle Safety System Harness Solutions
• Commercial & Domestic Appliance Wiring Sets
• Battery Cable Assembly
• Kitting Services

Production Equipment & Services

Cutting & Stripping

A full range of automated Cutting & Stripping machines by Komax for processing:

• Single core cables from 34 to 2 AWG
• Multicore cables up to 30mm diameter
• Heat shrink, sleeving, tubing up to 100mm diameter

Crimping

• A range of automated crimp presses & applicator heads for JST, Molex, TE, Deutsch, Amphenol and Poitronic terminals
• A range of bench mounted Mil-Spec pneumatic crimpers for circular crimp terminals of all sizes
• IDC Crimp tools for ribbon cable assemblies
• Over 500 manual crimp tools covering every terminal type

Soldering

Fully-equiped solder stations with experienced technicians, for tinning, splicing, and soldered connections

Overmoulding

Bespoke overmoulding solutions, from cable splitters to connector back-end waterproofing and sealing

Sleeving & Shielding

Extensive sleeving and shielding options, including braided, spiral wrap, foil, conductive shielding, and expandable sleeving for abrasion resistance, and to protect against electromagnetic interference and environmental factors.

Lacing, Taping, Bundling & Securing

Custom bundling solutions to ensure neat, durable, and reliable organization of wiring systems, constructed to NASA-STD-8739.4

Cable Coiling

Bespoke coiled/curly/retractable PVC and PUR cables to meet specific applications

Screwdriver Work

Manual and electric screwdriver stations with precise torque settings to ensure accurate and secure fastening

Design & Prototyping

Custom solutions tailored to specific requirements, from initial concept to rapid prototyping for functional testing and validation before full-scale production

Testing, Diagnostics & Reworking

Robust testing, diagnostics, and reworking services, using advanced equipment to ensure quality and performance, identify and troubleshoot issues, and meet exacting standards and specifications