The customized production of cables and wires – including cutting, stripping, crimping, soldering and the attachment of connectors, wire end ferrules or shielding.
At TPS Elektronik, we design, build, and test custom cable and wire harness assembly for electronics, industrial equipment, vehicles, and defense. From simple jumpers to complex box build assembly with power, signal, RF, fiber, and even pneumatic lines (connectors for air hose), our cable assembly manufacturing delivers repeatable quality, short lead-times, and clear documentation.
What We Build
Wire Harnesses & Power Looms
- Multicore and discrete harnesses, splices, breakouts, and overmolded strain reliefs.
- Jacket options: PVC, TPE, PUR, silicone, PTFE/FEP; shielding (foil/braid) per EMC needs.
- Identification: heat-shrink labels, laser marking, barcodes/QR.
RF / Coaxial Assemblies
- SMA connectors / SMA cable, smb connector, tnc connector, bnc plug to bnc plug jumpers, sma plug to sma plug leads, BNC pigtails (cable to BNC connector).
- Accessories & adapters: male to male adapter, male to female SMA adapter with flange, protective SMA cap.
- Test: VNA sweep and TDR for impedance, insertion/return loss.
Fiber Optic Cable Assembly
- Fiber optic cable and connectors: SC connector / optical connector SC / SC connector fiber, ST connector, LC connectors, LC LC connector fiber patch cords.
- Test: IL/RL measurement, ferrule end-face inspection; OTDR on request.
Circular & Harsh-Duty
- M8/M12, push-pull, and circular connectors up to IP67/69K.
- Defense: military spec connectors, mil spec plug, ruggedized backshells and boots for military cable assembly.
Vehicle, Industrial & Electronics
- Automotive cable assembly, robots and machinery industrial cable assembly, and high-mix electronic cable assembly for EMS builds.
- Thermocouples and sensors, including SMPW miniature thermocouple connectors and accessories.
Processes & Workmanship
- Automated cut/strip, semi-auto and applicator-based crimps, selective soldering, tinning, potting, and overmolding.
- Precision terminations for cable connector families (crimp, IDC, insulation-piercing, screw, and solder cups).
- Deburring and edge prep on custom metalbacks/plates; panel integration during box build assembly.
- Workmanship to IPC/WHMA-A-620 Class II/III (as specified), with pull-test sampling and 100% continuity checks.
- Traceable lot control and traveler documentation for regulated programs.
RF & Coax: Common Builds
- BNC jumpers: bnc a bnc (BNC-to-BNC), right-angle and bulkhead options.
- SMA families: sma plug to sma plug jumpers, semi-rigid/hand-formable leads, panel feed-throughs, male to female SMA adapter with flange, dust SMA cap.
- Mixed families: smb connector, tnc connector, and BNC panel pigtails (cable to BNC connector).
Why it matters: Proper cable, dielectric, braid coverage, and connector selection preserve impedance and reduce VSWR. We document cut lengths, strip dimensions, and torque specs to keep RF performance consistent.
Fiber Optics: Clean, Low-Loss, Ready to Route
- Polishes: UPC/APC per application.
- Connector families: SC connector, ST connector, LC connectors (simplex/duplex), plus LC LC connector fiber jumpers.
- Assemblies shipped with IL/RL results; options for bend-insensitive fiber and armored jackets.
Circular, Military & Specialty
- Industrial fieldbus and sensor lines with circular connectors (M8/M12), PUR cables for flex and oil resistance.
- Rugged/defense programs using military spec connectors and mil spec plug call-outs, backshell sealing, EMI spring fingers, and lacing.
- Electro-pneumatic looms combining signal, power, and connectors for air hose in one routed assembly.
Engineering Support (DFM)
- Connector selection & alternatives (availability, derating, retention).
- Gauge, flex-life, bend-radius, and routing studies for harness boards.
- Shielding/grounding strategy, drain wires, and 360° terminations.
- Environmental choices (temperature, fluids, UV) and ingress protection targets.
Testing & Documentation
- Electrical: 100% continuity and pin-map verification; hi-pot/insulation resistance on power harnesses.
- RF: VNA reports with frequency bands and pass/fail limits.
- Fiber: insertion/return loss certs; OTDR traces when specified.
- Mechanical: pull-force sampling and visual inspection criteria.
- Full device pack with drawings, BoM, revision, and serialization.
Typical Deliverables
- Custom wire harness assembly for control panels and machinery.
- Cable assembly services for RF/fiber/power in one kit.
- Tailored custom cable assembly services for low-volume prototypes up to scaled production.
- Partnerships as a wire harness assembly manufacturer to OEM standards and schedules.