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  1. The Manufacturing Process of Wire Harnesses

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    Wire harnesses consist of bundles of wire, cable, or subassemblies, combined with other conductive materials, and they are used to transmit electricity in various applications. The bundling of these components makes it easier to install electrical components for signaling or power transmission. In addition, other benefits of using wire harnesses include increased productivity, lower costs, and improved safety by minimizing trip hazards and wire damage.

    What Are Wire Harnesses Used for?

    A wire harness, also known as a wiring assembly or cable harness, groups multiple wires, cables, or subassemblies to supply electrical power or transmit signals in many applications.

    Wire harnesses have multiple applications and uses that make them suitable for many industries. A few of the main markets that use wire harnesses include the medical, military, and industrial industries. The transportation industry also frequently uses them in automobiles, trucks, buses, and planes. Other applications include industrial equipment, construction machinery, household appliances, and electronics.

    The Manufacturing Process of Wire Harnesses

    The wire harness manufacturing process ranges from basic to complex, depending on the end product. While it can be challenging, time-consuming, and task-oriented, a streamlined manufacturing process helps maintain efficiency and quality with each wire harness. The following is a breakdown of the different steps of the process and what they entail:

    Design

    While wire harnesses often appear simple, a clear, accurate design phase is critical to setting production and the manufacturing process up for success. This stage may involve choosing harness components, specifying different colors to identify specific wires, specifying all wire and cable lengths, and various other details.

    Prototyping

    Following the design stage, prototyping takes place. This entails developing a physical product based on the chosen design specifications. In the process, manufacturers can identify areas for improvement and determine how to approach the rest of the manufacturing process. This helps ensure optimal quality and process performance before beginning the first production run.

    Production & Assembly

    During production and assembly, manufacturers must meet design specifications and make sure the end product meets quality standards with minimal risk of errors. The production process still heavily relies on manual assembly even as manufacturing becomes increasingly automated.

    Throughout this stage, manufacturers typically complete three main steps:

    • Wire Cutting — The first step in the production phase involves cutting wires to their designated lengths using a wire-cutting machine.
    • Stripping and Connections — After cutting, the next step entails stripping the wire ends to expose their cores, which allows for the attachment of connector housings, terminals, or modules.
    • Assembly — The last step is the wire harness assembly process, which involves putting together the wire harness using an assembly board or workbench to put the final product together based on design specifications.

    Testing

    Following the core manufacturing process, manufacturers test the end product for quality assurance purposes. If the product meets quality and performance standards, the manufacturer ships the final product to the client.

    Top-Quality Wire Harnesses from Electro-Prep

    Various applications require reliable wire harnesses for transmitting electricity/data. If you’re in need of a wire harness for your application, Electro-prep can manufacture custom wire harnesses based on your unique requirements.

    To learn more about our wire harness manufacturing capabilities, contact us today. If you would like to get started, request a quote from us and we’ll connect you with one of our experts.

  2. Ribbon Cables

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    Also called a planar cable or flat ribbon cable, a ribbon cable has a wide, flat rectangular shape that resembles a ribbon. Each ribbon cable holds parallel wires that run on a flat plane. The distinct design makes it easier to work with when space is limited. Learn more about the types of ribbon cables, their advantages, and what to consider when choosing the right cables for your application.

    Types of Ribbon Cables

    Ribbon cables are available in a few different styles and configurations. The most popular types from most common to least common are: 

    • Standard. The standard ribbon cable is identified by its gray color and is commonly used for mass termination applications.
    • Rainbow. Rainbow ribbon cables are color-coded standard cables, which make organization and identification easier. In some cases, each colored ribbon is split into individual terminations.
    • Round-to-flat. This type of cable starts bundled in a circular shape, then flattens into a ribbon. The round-to-flat ribbon cable is adaptable and ideal in tight spaces.
    • Twisted flat. A variant of standard ribbon cables, twisted flat ribbon cables have pairs of conductors that are twisted and bonded together. They have alternating twisted and untwisted parallel sections. Distinct from twisted pair cables, a twisted flat ribbon cable has parts of the cable that are not twisted. This design allows the connectors and PCB headers to be terminated with conventional IDC ribbon cabling techniques.
    • Bonded. Bonded ribbon cables lack the flexibility of other ribbon cable types, but bonded cables simplify mass termination. The bonded design better organizes the cables from one end to the other.

    Considerations for Choosing Ribbon Cables

    When selecting ribbon cables for your application, consider the following specifications:

    • Pitch. The pitch pertains to the spacing of conductors within a ribbon cable. Common pitch measurements are 0.5 mm, 1 mm, 1.25 mm, and 2 mm. The correct pitch will vary based on various ribbon cable requirements.
    • Extreme temperatures. Basic ribbon cables work just fine in moderate temperatures. For high-temperature environments, a silicon jacket may be necessary to protect the ribbon cable.
    • Flexibility. A standard ribbon cable is very flexible. For settings with extremely limited space, you may need to order a customized ribbon cable with greater flexibility.
    • Long life. Choose ribbon cables that have been tested and rated for longevity.
    • Fire resistance. Fire resistance is important for both the safety and functionality of the electrical device. Be sure to choose a ribbon cable that is fully compliant with the fire safety regulations of its intended application. 

    Advantages of Standard Copper Conductor Ribbon Cables

    The key advantages of ribbon cables are flexibility, customizability, space efficiency, and noise reduction. In the past, ribbon cables had limited applications due to unique termination techniques. However, modern innovations in ribbon cable technology have enabled engineers to use standard cable preparation tools and automation. Now, ribbon cables can be mass terminated by solder-cup connectors or crimp contacts and configured for a wide range of electrical applications.

    Reliable Ribbon Cables From Electro-Prep

    The expert team at Electro-Prep can help you design ribbon cables tailored to your project. All of our employees are trained in-house, allowing us to provide a consultative approach for every client. We can provide you with the ideal ribbon cable paired with desired specifications to match your project’s needs. Electro-Prep offers customizable options that include:

    • 2 to 100 conductors in wide-spacing to high-density configurations
    • MDR, IDC, and other connector options
    • Integration with electronic components and materials
    • Full electrical continuity testing with Cirrus test systems
    • Flat flexible cable (FFC) alternatives

    Contact us today to learn more about our products and capabilities. 

  3. Wire Harness vs. Cable Assembly

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    Cable assemblies and wire harnesses are often referred to interchangeably because they both provide power to electrical devices. However, they are two different kinds of products.

    A wire harness is a bundle of wires organized together by a low-cost exterior wrap or sleeving. The wires are electrically conductive material, such as copper or aluminum. A cable assembly is a collection of cables or wires shielded by a stronger exterior material, like vinyl, thermoplastic, or thermoplastic rubber. Each cable is made up of at least two wires, which are laid out or braided together within the cable jacket.

    Here you’ll learn more about wire harnesses and cable assemblies, including their respective applications.

    Wire HarnessesWire Harness vs. Cable Assembly: Similarities

    The primary functions of both a wire harness and a cable assembly are to protect and organize wires or cables that conduct electrical currents. Both products also come protected by an insulating sleeve made of plastic or rubber, but the strength of this layer depends on whether it is a wire harness or cable assembly. In general, this layer protects the sensitive wires and cables from corrosion, shock, and impacts in their specific environments.

    Wire Harness vs. Cable Assembly: Differences

    Wire harnesses and cable assemblies are effective in different applications. The materials used in both products are generally the same, but the toughness of these materials differs.

    Wire harnesses offer physical support for wires in protected spaces, so their insulating wrap or sleeving—usually made of PVC or plastic—provides sufficient protection for these specific environments. Unlike cable assemblies, wire harnesses are not intended for applications with extreme environmental exposure, such as dust, heat, friction, and moisture. Cable assemblies feature a durable encasement made of thermoplastic rubber, shrink-wrapped thermoplastic, or vinyl to protect electrical components from these harsh outdoor conditions. Cable assemblies are also easier to thread around tight spaces because each bundle of cables are grouped together in one sheath.

    In terms of cost, wire harnesses are less expensive than cable assemblies. Wire harnesses require less material and labor to manufacture, and their cost reflects their relatively limited use cases. Cable assemblies offer a higher level of protection in a variety of harsh environments, so they are typically available at a higher price point. 

    Wire Harness vs. Cable Assembly: Applications

    Wire harnesses are common in these industries and applications:

    • Airplane engines 
    • Commercial and residential wiring
    • Car dashboards
    • Computers
    • Electronics
    • Garage door openers
    • Soda machines

    Cable assemblies are used in many industries, including: 

    • Military
    • Aerospace
    • Oil & gas electronics
    • Healthcare

    High-Quality Wire Harnesses and Cable Assemblies From Electro-Prep

    Wire harnesses and cable assemblies both protect and organize wires that carry electrical signals. However, their differences determine the right application for each one. 

    Established in 1977, Electro-Prep is a turnkey contract manufacturer of custom cable assemblies, wire harnesses, box builds, and other custom electromechanical assemblies. As an ISO 9001:2015 certified company, we are committed to high quality control standards, customer satisfaction, and continuous improvement. Contact us today to learn more about our products and services, or request a quote to get your project started.

  4. Case Studies

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    As a trusted provider of custom wire and cable assemblies, Electro-Prep delivers comprehensive solutions for demanding industries. Our services provide benefits such as improved design for manufacturability, reduced lead times, and products that meet rigorous testing and quality standards. These case studies outline solutions Electro-Prep has provided for customers in several diverse industries. 

    Custom Printed Circuit Board (PCB) Wire Harness (Spider Board) for a Military Application

    In addition to wire harnesses and subassemblies, Electro-Prep, Inc. is also a trusted provider of “spider board assemblies” to a DOD contractor. As the primary assembly provider for the entire PCBA assembly, we deliver high standards and unmatched service. In this case study, Electro-Prep designed and now constructs 11 different wire harness assemblies for a military application. 

    The customer supplies us with printed circuit boards and we then make all the solder connections as well as perform all of the final assembly work for all 11 wire harnesses. During this process we:

    • Use a wide array of terminal types as well as rectangular connectors to build a variety of wire harness assemblies
    • Lay out the wiring and make both soldered and crimped terminations
    • Make SMD connections using precision fine-tip soldering techniques and then protect the wire from wear damage by using nylon sleeving. 

    Each board undergoes visual inspection and full electrical testing before it is shipped to the customer. Wire harness assemblies from Electro-Prep are built to IPC-620 workmanship standards as well as J-STD soldering standards and can be supplied in medium to high volume quantities. 

    Custom Manufactured Electromechanical Assembled Box-Build (Junction Box) for Water Purification Industry

    Electro-Prep supplies junction boxes for a multinational company in the water purification industry. This company originally approached us for a turnkey electromechanical assembly solution. We worked closely with them to engineer an electromechanical box-build that met budget and quality criteria. 

    Electro-Prep created a design that featured pressure-rated watertight housing. However, after it was determined that creating this custom item would extend beyond the company’s budget, we quickly began investigating acceptable alternatives. Within a few days, we located a standard housing that, with minor modifications, would meet cost and design objectives. 

    The finalized electromechanical assembly consists of watertight housing, custom gaskets, cable glands, and DIN rail terminal blocks. Electro-Prep developed custom tooling that optimizes the speed and accuracy of the assembly process and guarantees timely product delivery. Our quality assurance analytics ensure UL standards, as well as the client’s specified pressure tolerances, are met. 

    Custom Wire Harness for Marine Industry

    Electro-Prep improved product production and assembly time for a marine industry manufacturer that produces a wide array of unmanned underwater vehicles (UUVs). We developed a solution for binding and combining wires into a single harness, streamlining the vehicle’s wiring process while complying with industry performance and safety standards. 

    Throughout this process we:

    • Designed and fabricated a subsea qualified wire harness using forming boards. 
    • Created a design with manufacturability in mind, ensuring the highest possible degree of repeatability in the final product. 
    • Employed semi-automatic and hand crimping tools to minimize production time. 
    • Built custom-engineered fixtures to perform 100% continuity testing. 

    This harness combines multi-conductor cable with discrete wires, rectangular connectors, splicing, and soldiered terminations. We also use military wire lacing as it is the easiest for the company’s assemblers to work with when installing the harness in tight locations. 

    Case Studies from Electro-Prep

    Electro-Prep provides custom-engineered solutions that help take businesses to the next level. For more information on our capabilities and services, contact us today or request a quote to get started. 

  5. Electromechanical Assemblies 101

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    Choosing the right electromechanical assembly manufacturer is critical to the success of your program and associated projects. The right business partner can accommodate your design needs, deliver assemblies on time and within budget, and provide reliable support for every stage of the project. To ensure your assembly is built to the highest standards, your manufacturer will need the following information:

    • Bill of materials (BOM)
    • Drawings 
    • Schematics
    • Wire run lists
    • Testing protocols
    • Sample units

    With this information, your preferred manufacturer can verify if they have the right capabilities and availability to manage your project successfully. 

    What Is An Electromechanical Assembly?

    Electromechanical assemblies are often found in electrical and electronic systems and consist of a variety of electromechanical components and subassemblies that perform a wide range of functions. Mechanical assembly is the process of incorporating these components and subassemblies into a cohesive system that can produce more advanced functionality.

    One of the most common types of electromechanical assemblies is a box build. Box builds or system integrations can be simple or complex and implement a box or other similar enclosure to house the components of the assembly. The manufacturer will often route the cables and wires from the enclosure to their intended destination, creating a compact, efficient solution.

    Manufacturers use specialized tools and equipment to produce assemblies at scale, and different service providers will offer different manufacturing and assembly capabilities.

    Benefits of Electromechanical Assemblies

    Choosing the right manufacturer for electromechanical assemblies can optimize your business processes and streamline the production of new products. Some of the benefits of choosing Electro-Prep for manufacturing electromechanical assemblies include:

    • Complete Engineering and Design Support: Along with managing the physical construction of electromechanical assemblies, our engineering teams can support design processes, testing, and design improvement processes. This allows for more efficient production of superior products, as we can streamline the design to fit cost-effective manufacturing processes with the fewest steps necessary.
    • Detailed Document Control: We are a professional electromechanical assembly manufacturer with turnkey solutions and can assist with complete document control. Through the use of enhanced engineering software, we can provide important documentation, including bills of material, prototyping and testing documentation, as well as clear product specifications.
    • Engineering and Manufacturing to Cost: By working with a single service provider, companies can simplify logistics and reduce costs, both for themselves and their intended target market while producing a higher quality product.
    • Prototyping: Many complex electromechanical assemblies need to undergo multiple virtual or physical revisions to optimize the design for functionality and production. Our team can ensure your products are safe, compliant with applicable standards and regulations, and constructed with the optimal materials and configurations through prototyping before production begins.

    Components and Sub-Assemblies in Electromechanical Assemblies

    Electromechanical assemblies often include the following components:

    • Custom Wire Harnesses and Cable Assemblies: Custom wiring assemblies disperse electrical currents to the correct parts and subassemblies in the system. We design them to be rated to perform based on your assembly’s specifications and to extend the lifespan of the product.
    • DIN Rails: Mounting rails in box-builds can streamline assembly by simplifying mounting and ensuring fragile components have enough space and stability.
    • Pneumatics: Complex assemblies may have pneumatic sub-assemblies and components such as valves, pistons, air regulators, and more.
    • Power Supplies: Power supplies convert the voltage, current, and frequency of electricity from a power source to fit the needs of the assembly.
    • Printed Circuit Boards (PCBs): PCBs are a modern alternative to wire circuit boards. They are more compact, efficient, and durable.
    • Programmable Logic Controllers (PLCs): PLCs are the control units that manage the functions of sub-assemblies within the assembly. They gather and compute data to initiate outputs based on previously determined parameters.
    • Relays: These components open and close circuits based on output commands from the assembly’s PLC.
    • Safety Components: Assemblies require safety components like sensors, breakers, and switches that mitigate the risk of equipment damage and injuries to users.

    Electromechanical Assemblies From Electro-Prep

    At Electro-Prep, we specialize in providing turnkey electromechanical assembly services. To learn more about our capabilities, download our eBook, “The Ultimate Guide To Electro-Mechanical Assemblies & Box-Builds.” For over 40 years, our engineering teams have designed, manufactured, and assembled complex assemblies. Contact us today to learn more about our capabilities or request a quote to get your project started.

  6. Box-Build Assembly Process: A Quick Guide

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    Box-builds refer to the combination of subassemblies and/or electro-mechanical components within a panel or enclosure. Depending on the specifications of your particular application, box-builds can either be a simple installation of a single PCB in a small enclosure or a highly complex and intricate installation of numerous components and subassemblies into large panels. 

    Box-Build Assembly Process

    While box-builds can vary significantly based on the components involved and the complexity of the final product, most processes follow the same basic steps. These steps are:

    1. Project Preparation. Before the project can begin, your box-build manufacturer needs documentation to ensure they can fully meet the needs of the project. This documentation includes design files, a bill of materials (BOM), schematics, testing data, and more. The more complete the documentation from the start, the better the service provider can gauge their ability to manage the assembly project and lower the risk of error.
    2. Testing the Components. The individual electrical components and sub-assemblies will be tested to ensure they each perform according to their specifications prior to installation.
    3. Preparing the Wires and Cables. Box-build manufacturers will cut, strip, crimp, and label the wires and cable assemblies prior to configuring them within the enclosure.
    4. Assembly. Box-build manufacturers will install and connect all of the components and wiring within the box from the bottom up.
    5. Labeling and Testing/Inspecting. At this stage, the builders label the individual components and sub-assemblies and test/inspect the entire assembly at defined intervals.
    6. Software Installation. Complex electronic assemblies also have software to make the assembly function. Box-builders will install the software and test it.

    Typical Components and Sub-Assemblies in Box-Builds

    Simple and complex box-builds can incorporate a wide range of components, subassemblies, and hardware. The most common elements in a box-build include:

    • Cable Assemblies
    • Custom Wire Harnesses
    • DIN Rails
    • Pneumatic Systems
    • Power Supplies
    • Printed Circuit Boards (PCBs)
    • Relays
    • Safety Components
    • Programmable Logic Controllers (PLCs)

    Benefits of Partnering With a Box-Build Expert

    Partnering with the right box-build expert can streamline your production and ensure a higher degree of product quality and longer-lasting assemblies. Some of the benefits of partnering with an experienced expert in the industry include:

    • Increasing Cost-Effectiveness and Adhering to Budget Constraints. Box-build experts can optimize the production process to guarantee that your product has the most cost-effective and efficient design. Working with one vendor also helps to reduce lead time and streamline assembly operations.
    • Streamlining the Production Process. Partnering with a box-build expert eliminates the need to maintain communication with multiple suppliers and manage the production process. This allows you to focus your energy on other important business areas where you’re the experts.
    • Increasing Product and Process Quality. Box-build experts have the tools, resources, and supply partners to ensure optimal product consistency and high-quality box-build solutions.
    • Reduced Risk of Costly Miscommunication. If you work with multiple suppliers at once, you automatically have a higher risk for miscommunication and errors. Partnering with a box-build expert eliminates this risk, ensuring your product is delivered as you intended.

    Box-Build Assemblies From Electro-Prep

    At Electro-Prep, we have a long history as a leading service provider in the box-build industry. Our employees are certified to meet IPC-620A (IPC/WHMA-A-620) and J-STD-001 standards, and our company is ISO 9001:2015 certified. We’re committed to providing high-quality services during every stage of production and assembly to ensure your product meets your every need. Contact us today to learn more about our box-build capabilities, or request a quote to get your project started.

  7. Wire Insulation – A Material Guide | Types and Applications

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    Wire insulation is a crucial outer layer applied to wires and cables to protect the wires from external conditions. The insulation or jacket simultaneously prevents current from leaking from the wires into the surrounding area. To meet the needs of a diverse range of wire materials, settings, and applications, wire insulation is available in a variety of types and materials.

    Materials Commonly Used for Wire Insulation

    Depending on the application, wire insulation can be composed of many different materials, including plastic, rubber, and fluoropolymers. 

    Plastic

    Plastics exhibit a number of useful characteristics ideal for wire insulation, including ductility, electrical resistance, UV resistance, and fire resistance. Below are popular plastics used in electrical wire insulation: 

    • Polyvinyl Chloride (PVC): PVC is one of the most commonly used insulation materials due to its cost effectiveness and high durability. It exhibits high resistance to fire and chemicals, and can maintain its shape and durability in temperatures from -55° C up to 105° C.
    • Semi-Rigid PVC (SR-PVC): SR-PVC can withstand abrasion and has a high level of resistance to acids, alkalis, water, and heat.
    • Plenum Polyvinyl Chloride (Plenum PVC): Plenum PVC is engineered with greater fire resistance for fire-rated use in plenum spaces.
    • Polyethylene (PE): PE is denser and harder than PVC. It is highly electrically insulative and especially resistant to cracking at temperatures between -65° C and 80° C.
    • Polypropylene (PP): Polypropylene has higher temperature resistance than PE, with operating temperatures between 30° C to 80° C. 
    • Polyurethane (PUR): PUR is flexible, with high water, chemical, and abrasion resistance. It provides excellent performance in marine applications and low temperatures from  -62° C to 93° C.
    • Chlorinated Polyethylene (CPE): CPE is a cost-effective insulation with excellent resistance to oil, heat, and outdoor conditions.
    •  Nylon: Typically used as a secondary insulator over softer insulation materials. Nylon provides a flexible protective layer with poor water resistance.

    Rubber

    Rubber materials are more flexible than plastic, especially at lower temperatures. Rubber materials used for wire insulation include: 

    • Thermoplastic Rubber (TPR): TPR is resistant to a broad range of temperatures, UV radiation, and wear. 
    • Neoprene (Polychloroprene): Neoprene exhibits superior abrasion and cut resistance, as well as resistance to oils and solvents. 
    • Styrene Butadiene Rubber (SBR): SBR has greater temperature resistance than neoprene, and is typically used for MIL cables at temperatures from -55° C to 85° C.
    • Silicone: Valued for its high flexibility, silicone has exceptional flame retardance and heat resistance up to 180° C.
    • Fiberglass: Fiberglass is used for extremely high temperature applications up to 482° C. It is also resistant to chemicals and water.
    • Ethylene Propylene Rubber (EPR): EPR is very resistant to heat, oxidation, water acids, alkalis, alcohol, and electrical currents. 
    • Chlorosulfonated Polyethylene (CSPE): Perfect for low-voltage applications, CSPE has good chemical and UV resistance, and operates at a broad range of temperatures.
    • Ethylene Propylene Diene Monomer (EPDM): EPDM has low conductivity, is extremely flexible, and performs at temperatures between -45° C and 177° C.

    Fluoropolymer

    Fluoropolymers are polymers that are especially resistant to bases, acids, and solvents. Popular fluoropolymers used in electrical insulation include:

    • Perfluoroalkoxy (PFA): PFA is an excellent option for enhanced electrical efficiency due to its low dissipation factor. It can withstand temperatures from -65° C to 250° C, but is pricier than other insulation options. 
    • Polytetrafluoroethylene (PTFE): PTFE offers exceptional resistance to oil, chemicals, heat, and moisture. It is highly flexible in a broad range of temperatures, from -73° C to 204° C.
    • Fluorinated Ethylene Propylene (FEP): FEP has excellent electrical insulation properties, as well as UV and chemical resistance. It is extremely tough and flexible. 
    • Ethylene tetrafluoroethylene (ETFE): ETFE exhibits excellent corrosion resistance, a high melting temperature, and superior resistance to chemicals, electrical current, and high-energy radiation.
    •  Halar® ethylene chlorotrifluoroethylene (ECTFE): A melt-processable polymer that exhibits superior strength, chemical resistance, and flexibility, ECTFE can also be extruded and braided for extra abrasion protection.
    • Polyvinylidene Fluoride (PVDF): PVDF is an economical insulation that is lightweight, flexible, and flame resistant to UL 910 standards for plenum cables.

    Wire Insulation Applications

    The type of material used for wire insulation is largely determined by the application for which it is used. 

    Plastic wire insulation is used for:

    • Medical applications
    • Food & beverage industry
    • Military purposes
    • Industrial power plants
    • Interior spaces either beneath raised floors or above dropped ceilings
    • Marine and low-temperature environments
    • Power & control cable applications
    • CPE cable insulation displays

    Rubber wire insulation is used for:

    • Heat treating
    • Glass and ceramic kilns
    • Foundries
    • Aluminum processing

    Fluoropolymer wire insulation is used for:

    • Military applications
    • Automotive industry
    • Household appliances

    Premium Wire Insulation From Electro-Prep, Inc.

    At Electro-Prep, we have the knowledge, equipment, and skills necessary to produce quality wire and cable insulation from a variety of materials for virtually any application. Contact us today to learn more about our selection of insulation materials or request a quote. 

  8. PVC vs Teflon Insulated Wire

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    Wire insulation is essential for preventing electrical shorts between conductors. There are several types of wire insulations to choose from, and each material has different characteristics and advantages. This blog post will discuss the differences between PVC and Teflon wire insulation, as well as some of the most common applications of each type. 

    PVC Wire

    PVC, or polyvinyl chloride, is a highly durable and versatile thermoplastic material that has several beneficial characteristics for wire insulation applications. For example, in addition to being moisture, flame, and abrasion-resistant, PVC functions optimally in temperatures ranging from -55 °C to 105 °C. It is also resistant to UV and many types of chemicals, including acids, oils, and alkalis.

    PVC offers a less expensive material option for wire insulation. This makes it a popular choice for applications involving a large volume of wire or where cost is a significant consideration. It is the most readily available wire insulation material choice and provides a long service life, typically exceeding 25 to 30 years. PVC is also easy to process and recycle. 

    Teflon Insulated Wire

    Teflon® is a registered trademark name for the material polytetrafluoroethylene (PTFE). This synthetic fluoropolymer is one of the most popular insulating compounds. PTFE can withstand extreme temperature fluctuations between -90 °C to 260 °C and is used in many challenging environments. It is also highly durable and exhibits excellent electrical properties. 

    In comparison to wires insulated through extrusion, PTFE insulated wire is tape-wrapped and therefore features a uniform thickness. For this reason, PTFE tends to be a higher-grade wire and is typically significantly more expensive than PVC insulated wire. 

    PVC vs Teflon Insulated Wire Applications

    PVC and Teflon have many similar properties. Both materials are durable, flexible, and resistant to chemicals and UV light. However, their key differences cause them to be used in different applications. For example, while PVC can be used as both an insulation and jacketing material, Teflon is typically only used as insulation. 

    Applications for PVC wire insulation and cable jacketing include:

    • Appliance wiring industry
    • Communications industry
    • Medical industry 
    • OEM applications 
    • Oil and gas industry

    Teflon insulation wire offers a reliable insulation solution for applications such as:

    • Aerospace industry
    • Coaxial communications
    • Military and defense industry
    • OEM appliance wiring
    • Oil and gas industry

    Electro-Prep Meets All Your Wire and Cable Needs

    Choosing the best type of wire insulation is an important way to ensure your assembly functions optimally and delivers a long service life. PVC and Teflon are two popular materials for wire insulation applications, and choosing which one to use depends on factors such as the environment your assembly will be used in, your budget, and more. 

    Electro-Prep has over 40 years of experience delivering reliable wire harnesses and cable assemblies. We can help you select the best insulation material and achieve an assembly that meets even the most rigorous demands. To learn more about our services, contact us today. When you’re ready to get started on your customized solution, request a quote.

  9. A Guide to the Different Types of Coaxial Cables

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    Coaxial cables are a type of transmission cable used to transmit radio frequency (RF) signals. They generally consist of four layers—the inner conductor layer, the inner conductor insulating layer, the conductive shield layer, and the insulating outer jacket layer. This shielded design enables signal carrying voltage to flow through the central conductor with minimal interference from outside electrical and/or magnetic fields. 

    There are many types of coaxial cables available—varying in design and size—to suit different applications. One of the key design elements by which coaxial cables can be categorized is connector type—i.e., the mechanism that connects the cable to other devices. Below, we highlight the advantages and disadvantages of several common types of coaxial cable, based on connector, as well as their typical applications. 

    BNC 

    BNC Coaxial CableBayonet Neill-Concelman (BNC) coaxial cable connectors are one of the most commonly used connector types. They feature a twist and snap bayonet connection design that requires a quarter-turn to form a connection. 

    Key advantages of BNC connectors include: 

    • Simple design. They have the simplest design of all coax cable connectors. 
    • Easy connection. They do not require any tools.
    • Small accidental disconnection risk. They lock the connection in place to prevent accidental disconnection caused by vibrations or other movements. 

    Some of the disadvantages include: 

    • Limited frequency range. They have a frequency range limited to DC-4 GHz.
    • High susceptibility to variations. They can experience variations in resistance and outer sleeve connection when exposed to mechanical vibrations. 

    Typical applications include commercial audio/video transmission systems and RF test equipment (e.g., frequency generators, network analyzers, and oscilloscopes).

    TNC

    TNC Coaxial CableThreaded Neill-Concelman (TNC) connectors are a miniature threaded variation of BNC connectors. However, they are waterproof and more rugged.

    Key advantages of TNC connectors include: 

    • High frequency capacities. They can operate with frequencies up to 11 GHz.
    • High mating cycle life. They can be used for up to and exceeding 500 cycles.
    • Low susceptibility to variations. They are less likely to experience variations in resistance and outer sleeve connection when exposed to mechanical vibrations.

    Some of the disadvantages include: 

    • Large size, heavy weight. They are heavier and larger than SMA connectors. 
    • Specific attachment requirements. They require a specific coaxial cable form.
    • Potential for higher loss. Right-angled versions have a slightly higher level of loss than straight-through connectors, which can be a concern in applications involving frequencies near the operational limit of the connector. 

    Typical applications include mobile telephones and RF antennas. 

    SMA

    SMA Coaxial CableSubminiature Version A (SMA) connectors are 50 Ω connectors. They are available in several formats, including male vs. female, straight-through vs. right-angled, and more. 

    Key advantages of SMA connectors include: 

    • Small size, light weight. They are smaller and lighter than TNC connectors, making them suitable for applications where size and weight are a concern.
    • High frequency capacities. They can operate with frequencies up to 18 GHz.

    Some of the disadvantages include: 

    • Less robustness. They are less suitable for use in harsh environments than larger connectors.
    • Unsuitable for frequent connection/disconnection. They are not designed for applications that require frequent connection and disconnection.

    Typical applications include microwave systems, telecommunications equipment, and Wi-Fi antennas.

    7/16 DIN

    7-16 DIN Coaxial Cable7/16 DIN (Deutsches Institut für Normung) connectors have a threaded design. They are typically used for high-wattage transmissions.

    Key advantages of 7/16 DIN connectors include: 

    • High intermodulation rejection. They offer higher intermodulation rejection than BNC or N connectors.
    • High power capacities. They handle higher power levels than most other connectors. 

    Some of the disadvantages include: 

    • Harder connection/disconnection requirements. They need a wrench for connection and disconnection.
    • Incongruous with US standards. They are generally used in Europe rather than the United States. 

    Typical applications are base stations, broadcast communication systems, and other situations involving multiple transmissions. 

    QMA

    QMA Coaxial CableQMA connectors are similar to SMA connectors. However, they have a snap-lock design that allows for faster and easier connection/disconnection and 360° rotational capabilities after connection that allows for better installation flexibility. 

    Other key advantages of QMA connectors include: 

    • High power capacities. They can handle higher power levels than some of the other connector types.
    • High frequency capacities. They can operate with frequencies up to 18 GHz.

    Their primary disadvantage is the lack of waterproofing. They are not suitable for use in environments where exposure to moisture is expected. However, they are ideal for use in industrial and communications applications that require the maintenance of the shielding barrier.

    MCX

    MCX Coaxial CableMicro coaxial (MCX) connectors are small form-factor connectors. They are designed for use in applications with size or space limitations. 

    Key advantages of MCX connectors include:

    • Similar to SMB connectors but are 30% smaller.
    • Easy installation. They have a snap-on coupling design that makes installation simple and quick.

    Some of the disadvantages include: 

    • Limited frequency range. They have a frequency range limited to DC-6 GHz.
    • Variable sizes. They can vary in size depending on the manufacturer.

    Typical applications include digital cellular systems, global positioning systems (GPS) devices, RF hardware, and TV tuner cards.

    RCA 

    RCA Coaxial CableRadio Corporation of America (RCA) connectors are also known as cinch connectors. They typically feature three color-coded jacks and plugs (Red, Yellow, and White). 

    Key advantages of RCA connectors include: 

    • Wide availability. They are readily available.  
    • Low cost. They are relatively inexpensive. 

    The main disadvantage is the color code system. It can be difficult for some users to navigate, especially in more complex systems. 

    Typical applications include audio and video systems, such as camcorders, digital cameras, stereo systems, and televisions.  

    Partner With Electro-Prep for Your Coaxial Cable Needs!

    Looking for a coaxial cable for your RF application? The experts at Electro-Prep are here to help! As a premier coaxial cable manufacturer, we are fully aware of the impact poorly designed and constructed cables can have on product performance. That’s why we employ a highly experienced and fully trained team who are committed to providing you with the highest quality cable solution. To learn more about our coaxial cable capabilities or discuss your requirements with one of our team members, contact us or request a quote today.

  10. The Critical Role of Box-Build Assemblies

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    What is a Box Build?

    box build assembliesA box build is an enclosure or panel used for the integration of a system’s electro-mechanical components. A box build can be as simple as a small plastic enclosure with just one or several components or more complex, with a larger enclosure designed for full system integration of multiple electro-mechanical components and assemblies. A box build typically involves the fabrication of the panel or enclosure, the routing of cables and wires, and the installation of sub-assemblies and components. These sub-assemblies and components may include:

    • Printed Circuit Boards 
    • Custom Cable Assemblies
    • DIN Rails
    • Power Supplies
    • Programmable Logic Controllers
    • Pneumatics
    • Relays / Logic
    • Safety Components

    Box Build Design Goals

    One of the most difficult challenges in manufacturing is finding the ideal balance between product design and product manufacturability. A product may have a design that makes it ideal for its intended purpose, but that design may be challenging to manufacture.

    Manufacturing challenges can result in quality issues and high product assembly costs. Designing a high quality, cost-effective box build is best accomplished when a box build manufacturer is consulted and included in the design phase whenever possible.

    Why Partner with Box Build Experts?

    Partnering with a box build expert often saves time and money by eliminating the need to manage numerous suppliers to provide components or create and manage the production process. When you work with a box build expert, you reduce the risk of miscommunication which may occur when working with multiple vendors regarding changes or other issues. This partnership also streamlines your assembly process and reduces lead times.

    Partnering with a manufacturer specializing in box build construction enables you to receive valuable input to optimize your box build design. A box build expert gives you access to integrated manufacturing processes that offer economies of scale that can prove extremely cost-effective, while maintaining the highest quality control possible.

    Outsourcing your box build can be extremely cost-effective compared to manufacturing the box internally. By working with one assembly partner rather than several, you can effectively maintain higher quality control and significantly reduce costs.

    Why Electro-Prep?

    At Electro-Prep, box builds are one of our specialties. We have over 40 years of experience providing high-quality, value-added products to our customers. Our team of engineers and technicians have the product knowledge and expertise to help you with any design or manufacturing issue that you may encounter. As one of our core competencies, our wire harnesses and cable assemblies are built in house as well, to maintain the highest possible quality control.

    Quality and service are our team’s top priorities. We are ISO 9001:2015 certified and have established a highly-skilled workforce with the discipline required to provide quality products and services. Our assembly team is certified to IPC-620A workmanship standards and J-STD-001.6 soldering standards, as well, with a certified trainer on staff. We take great pride in an outstanding, local customer service team and our products are manufactured and assembled in the USA.

    Contact Electro-Prep For Your Box Build Needs

    At Electro-Prep, we have a growing team of experts dedicated to providing our customers with the highest quality solutions. We provide products and services for a wide range of applications in vertical markets such as medical, electronic instrumentation, process control, military, industrial, and more. Each of our build boxes are custom designed and manufactured to meet your application’s exact specifications. To get started on your box build solutions, contact us or request a quote today.

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