C4ISR Cables
Overview of Capabilities
Engineering-Subject Matter Experts with Extensive Knowledge of Cable and Harness Assembly
The C4ISR Cables leadership team has years of experience in component design and sourcing, manufacturing and testing of all types of cable and harness assemblies. Our manufacturing engineers have the hands-on experience for building years of NPI cables and harnesses. The team also has years of estimating RFQ’s experience. This provides our customers with a very high level of expertise to offer improved performance and cost reductions for your prototype, FAI and production requirements. We also offer solutions to many known industry issues, such as the ability to bond mold materials to Nickel-Teflon plating utilized on many connectors today as one example.
Molded Cables
- Extensive knowledge and proven history of design of molds and high-volume production.
- Extensive knowledge of proven performance to bond many mold materials to many different jacket materials
- Prototype capability to provide 3D printed molds to validate your new mold designs for aesthetics, shape and size. Our 3D printing has a large printing size of 8” x 8” x 12”. The ABS material can be machined by drilled, tapped, sand and paint.
- C4ISR Cables can assist your design team with proven designs and materials utilized on fielded platforms.
- Assist your design team with application engineering for shielding, environmental and NBC requirements
- High pressure injection mold for materials like Estane Polyurethane, great selection for high volume applications
- 2-Part Chemical cure polyurethane meets Mil-M-24041 provides proven fielded platform experience for many decades. Great for heat sensitive materials, like USB cables, since there is no heat involved in this molding process. Great selection for pressure sensitive molding like covering of electronic components.
- Low pressure hot melt adhesives- polyamide and polyolefin. Great for coax cables and over mold of electronics.
- Proven history in developing cost reductions, workmanship documents, white papers and reverse engineering of new mold options for fielded platforms.
LEAN Mfg with Rapid Prototyping to Production
Supply Chain Expertise
The C4ISR Cables leadership team has decades of experience in component design and sourcing. Our proven history to manage our supply chain has provided the ability to receive the best pricing in the industry along with significant improved deliveries compared to the industry. Our ability to works on fast tracking new designs and alternate designs has also provided significant value. Our personal experience in working for many of the leaders in the connector industry also provides significant knowledge of interconnection products. The experience in managing a QPL’d, value added connector distributor also provides unique knowledge of the products used in the cable and harness industry.
Test & Measurement
We have multiple methods for testing. The fully automatic testing with connector mates is part of our core strategy, this provides significant value over testing by probes. The mating connectors will provide the mating forces, the proper clocking defined, and this simulates the installed condition. The fully automatic testing provides all these options:
- Test Optimization and Time Saving Features Test Re-engage – enables test to be paused after a failure and re-engaged after debugging, eliminating the need to repeat an already verified test sequence and save overall test times.
- Measure & Energize – measurement & energization is available from all available test points reducing overall test times. Mass HI Pot – provides complete test coverage in a fraction of the time required by conventional linear test methods.
- Activation & Energization – enables test sequence to energize relays to validate functions and verify safety features.
- SuperTrace – nets for complete color-coded connectivity map.
- Scan Testing – enables all test points to be scanned every 10 μs for discontinuity testing. Ideal for environment, stress, vibration, and thermal cycle testing.
All Test Data can be serialized and saved on our Server for future reference. The test performance report is dated and defines the person who performed the test.