Custom Engineering Solutions:
Wire Harnesses & Cable Assemblies

Are you ready to minimize design and production costs while optimizing quality and performance? We can provide cost-effective solutions with our wiring, cable, and component design engineering expertise.

Join forces with the skilled engineers at Kauffman Engineering, who excel at identifying and optimizing design and minimizing production costs while ensuring that quality and functionality are top of mind. We have created a reputation with our customers for using our experience in wiring, cable, and components to uncover ways to minimize expenses and reduce the production time for finished products.

Our team can support you with the engineering, redesign, or enhancement phases of product development. Our process improvement teams have the skilled expertise and experience to generate innovative ideas and put them into practice. Based on your specifications, we can create and implement a project action plan and carry it out to meet expectations. With our vast experience in continuous improvement and value added, value engineered (VAVE) knowledge, we regularly review design and process methods to benefit our customers.

Delivering Quality Products on Schedule

The team delivers high-quality designs and custom products on schedule 100% of the time through abiding by our Quality Management System (QMS) certified to ISO 9001. Our goods are registered and compliant with UL, CUL, and CSA Standards, and we provide FAI/PPAP samples per customer requirements.

Shipping Process includes:

  • Certificates of Conformance (COC)

  • Custom Labels

  • Bar Coding

  • Traceability Identification

  • Special Packaging

Quality Process includes:

  • Best in class automated wire processing equipment

  • Advanced computer-controlled crimp height and pull force inspection systems

  • Tailored test boards for assembly and testing of electrical circuits, continuity, physical layout of harness assemblies

With AutoCAD, E3, and other design technologies, our in-house tool shop enables us to swiftly design molds, terminal applicators, assembly fixtures, and test fixtures. Our tooling capabilities make rapid custom solutions a reality.

We can complete orders in smaller quantities and with quicker turnaround times due to our in-house extrusion capability. We can manufacture wire from 36 AWG to 4/0 in our facilities. We have presses that can create both our designs and any special stamping applications, ranging in size from 10 tons to 65 tons. We construct harnesses, assemblies, and systems using a range of materials, including steel, brass, tin-plated brass, copper terminals, and brackets.

Choose from a variety of lengths and colors for our extensive selection of expandable braided sleeving goods. For many applications, including those in the automotive industry and high-temperature machinery, we provide a variety of flame-retardant expandable braided sleeving. When in use, our expandable braided sleeving can nearly double in size.

Our industry-leading efficiency, quality, and consistency for both length and crimp integrity are powered by our automated cutting, terminating, and printing & heat stamping technologies. To guarantee consistently high-quality crimps, our quality department continuously monitors crimp height. We also provide resilient connections with Sonic Welding Technology where required.

Switches, resistors, thermistors, and capacitors are just a few of the components our programmable testers keep an eye on. Hi-Pot testing is required as a final step to protect wire harnesses from damage, guaranteeing dependable functionality. We can identify any flaws or issues with the wire harnesses before they are supplied to you with our electronic testing capabilities, reducing the possibility of having to pay for labor-intensive rework or repairs.

Kauffman Engineering provides circuit board assembly and electronic manufacturing services in addition to wire harness production. Our EMS staff adheres to stringent ESD guidelines and has IPC certification for both lead-filled and lead-free work cells. We can serve a wide range of industries with our automated through-hole, BGA, surface-mount assembly, and no-clean soldering methods. We provide a range of capabilities, including diagnostic and functional testing, as well as design for manufacturing assistance.

Contact Kauffman Engineering if you’re seeking complete wire harness and electronic manufacturing solutions for the HVAC industry. We are qualified, experienced, and equipped to provide items of the highest caliber that meet the needs of your application.

Our automated cut & strip process is efficient, preparing wires for additional operations such as IDC termination, single, double, and multiple conductor terminations, in-line and end splicing, and wire twisting for twisted pair production.

Kauffman Engineering has extensive experience in ribbon cable manufacturing, including custom ribbon cables that come in varying lengths, pitches, and connectors. The team’s proficiency in the exacting process is the reason we are the preferred choice for any RC application. We have the capability to produce ribbon cables with high pin counts and complex configurations, and we can also provide ribbon cable assemblies integrated with other components.

Kauffman provides an array of panel thicknesses and hole sizes that can be accommodated by our molding machines and grommets/overmolds. We can design molds that precisely fit your specifications, since we have the fastest turnaround time in the industry for new product tooling. We create high-quality wire harnesses that are tough, resilient, and able to survive harsh situations thanks to our advanced molding capabilities.

Kauffman Engineering is dedicated to continuous improvement every step of the way and guarantees customer success. Contact us to discover how we can enhance your applications.