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CAP-00 · Manufacturing CapabilitiesProcess
Process
Stack.
The four operational pillars of our shop floor: crimping, soldering, testing, and overmolding. Each capability is detailed below with calibration cadence, tooling library, applicable standards, and the specific quality failure modes we have eliminated.
Tooling library1,200+ dies
CalibrationAnnual cert
WorkmanshipIPC-620 C3
First-pass yield99.7%
Spec Index · CAPABILITIES
By spec, not by adjective.
CAP-0101
Crimping Process.
Calibrated crimping process: Molex CR1000, TE Pro-Crimper III, JST YC, Deutsch HDT-48-00, hex-crimp HV lugs.
Open spec CAP-0502Harness Board & Form Board.
Harness board / form board capability — CAD-to-fixture 1:1, EPLAN / Altium / DXF intake, ±2 mm branch tolerance, golden first-article validated.
Open spec CAP-0603IATF 16949 Certification.
IATF 16949 certified wire harness manufacturer — PPAP Level 1-5, dimensional CMM, IMDS submission, control plan, FMEA per AIAG.
Open spec CAP-0704Harsh Environment Cable Assembly.
Harsh environment cable assembly capability — MIL-STD-810G / SAE J1455 / ASTM B117.
Open spec CAP-0205Soldering & Splicing.
Soldering & splicing process: J-STD-001 Class 3, IPC-A-610 acceptance, ultrasonic wire-to-wire splice, lead-free SAC305 default, ESD-safe ANSI/ESD S20.
Open spec CAP-0306Testing & Inspection.
Testing & inspection process: CIRRIS 1000H 100% continuity, hipot to 1500 VAC, milliohm 4-wire Kelvin, pull-force per UL 758, IPC-A-620 visual, MIL-STD-202 environmental.
Open spec CAP-0407Overmolding Process.
Overmolding process: low-pressure polyurethane, hot-melt, USP Class VI silicone.
Open specCapability Stack · WHY_VEINWIRE
What the procurement deck never says.
CAP-0101
Connector-OEM tooling
Calibrated dies per Molex CR1000, TE Pro-Crimper, JST YC, Deutsch HDT, Amphenol AT specs.
CAP-0202
J-STD-001 solder
Lead-free Sn96.5/Ag3/Cu0.5 standard. Leaded option for legacy mil-spec. ESD-safe operator stations.
CAP-0303
CIRRIS 1000H continuity
Optical-fiber-stripped test fixtures, low-resistance milliohm option, hipot ramp to 5kV.
CAP-0404
5-axis CNC tooling
Overmold tools cut in-house. 5-10 day lead from approved drawing — no third-party tool shop wait.
CAP-0505
Pull-force qualification
Destructive pull test per UL 758 on first article + AQL 1.0 sample plan on production.
CAP-0606
IPC-A-620 visual standard
Class 2 and Class 3 visual inspection per IPC-A-620 acceptability criteria. Trained certified operators.
FAQ · CAPABILITIES_QUERIES
Hub-level questions.
How often is crimp tooling calibrated?+
Annually by third-party calibration lab with NIST-traceable certificates. Spot-check on every shift via the operator's torque/height/pull-force gauge. Calibration records retained 7 years.
Do you do destructive pull-force test on every lot?+
First article from every production lot is pulled to destruction per UL 758 spec. Sample pull-test per AQL 1.0 throughout production. 100% pull-force test available on request at additional cost.
Which solder specification do you build to?+
J-STD-001 Class 2 standard. J-STD-001 Class 3 for mission-critical (aerospace, medical, military). Lead-free SAC305 default; SN63/PB37 leaded available for legacy mil-spec programs.
What test equipment do you maintain?+
CIRRIS 1000H continuity (primary), Slaughter 1500VAC hipot, Megger insulation resistance, AEMC milliohm meter, Mark-10 force gauge for pull/torque, environmental chamber for thermal cycling.
How long does overmold tooling take to cut?+
5-10 business days from approved 3D tool drawing. 5-axis CNC cut on-site, no external tool shop in the loop. We design, cut, sample, and validate within one shop.
Can you handle very-fine-pitch crimping?+
Yes — down to 28 AWG on Molex Pico-Blade (1.25mm pitch), JST GH (1.25mm), Hirose DF11 (2mm). Below 30 AWG we recommend IDC or solder termination rather than crimp for reliable contact resistance.
Engage · CAPABILITIES_CTA
Move your capabilities program forward.
Submit RFQ or talk to engineering — response within 4 business hours. Response within 4 business hours. No obligation. Drawings stay under NDA.