Electrical wiring harness – manufacturing processes

Cutting, stripping and crimping wires on CNC machines

Our cable harness production is based on the highest precision and modern technologies. Thanks to our latest investment – ​​Komax Alpha 520, a fully automatic wire processing machine – we can fulfill orders even faster and more precisely.

The Alpha 520 enables automatic cutting, stripping and crimping of wires in a wide range of lengths, cross-sections and cable types, ensuring excellent quality and repeatability. It is an ideal solution for both small and large production runs.

 

Our machines for cutting, stripping and crimping wires:

  • Alpha 520
  • Alpha 355
  • Gamma 333
  • Schleuniger MultiStrip 9480
  • Schleuniger PowerStrip 9550 – a station equipped with a cable unwinder, coiler and bundling machine
  • Wirmec AM300 Quattro

Braiding wires

Cable braiding is a process of securing and organizing cable harnesses to increase their durability, flexibility and aesthetics. We use various techniques, such as tape wrapping, braiding synthetic fiber sheaths or using spiral tubes to provide optimal protection against abrasion, moisture and mechanical damage. Thanks to precise braiding, our cable harnesses meet the highest quality and safety standards, and are used in automotive, industrial and electronics.

We have the following machines for braiding cables:

Cobra 450

Braiding wires

Cable braiding is a process of securing and organizing cable harnesses to increase their durability, flexibility and aesthetics. We use various techniques, such as tape wrapping, braiding synthetic fiber sheaths or using spiral tubes to provide optimal protection against abrasion, moisture and mechanical damage. Thanks to precise braiding, our cable harnesses meet the highest quality and safety standards, and are used in automotive, industrial and electronics.

We have the following machines for braiding cables:

Cobra 450

Connecting elements by soldering

Connecting components by soldering is a key process in the production of our cable harnesses, ensuring durable, reliable and conductive connections. We use modern soldering techniques, both manual and automatic, ensuring the highest quality and precision.

Our soldered harnesses are used in demanding industries such as automotive, electronics and industry, meeting the highest quality and safety standards.

Connecting elements/wires using ultrasonic welding technology

Connecting wires using ultrasonic welding technology is a modern solution that provides durable, clean and conductive connections without the use of additional materials such as binders or fluxes.

Thanks to the use of advanced ultrasonic welding systems, this process allows for quick and precise connection of wires.

Thanks to investment in modern machinery, we guarantee high quality, repeatability and efficiency, meeting the rigorous requirements of our customers.

Ultrasonic welders:

  • Branson 2032 S

  • Sonobond WS 2026

Connecting elements/wires using ultrasonic welding technology

Connecting wires using ultrasonic welding technology is a modern solution that provides durable, clean and conductive connections without the use of additional materials such as binders or fluxes.

Thanks to the use of advanced ultrasonic welding systems, this process allows for quick and precise connection of wires.

Thanks to investment in modern machinery, we guarantee high quality, repeatability and efficiency, meeting the rigorous requirements of our customers.

Ultrasonic welders:

  • Branson 2032 S

  • Sonobond WS 2026

Tinning of wires

Tinning wires is a reliable method of protecting cable ends from corrosion and improving their conductivity. This process involves covering the exposed wires with a thin layer of tin, which not only increases the durability of the connections, but also facilitates further processing, e.g. soldering or assembly in terminals.

Thanks to the use of precise tinning methods, both in tin baths and by applying tin hot, we guarantee uniform coverage and excellent electrical properties of wires. This technology is widely used in electronics, automotive and automation industries, ensuring long-term protection and stability of connections even in the most demanding conditions.

Forming plastic parts – plastic injection

Forming plastic parts – plastic injection is a modern method of producing precise elements, which allows for the creation of durable, aesthetic and repeatable components. Thanks to injection technology, we can produce both small and large series of parts with complex shapes, meeting the highest quality requirements.

We have an advanced machine park that ensures precision, high efficiency and waste minimization, which translates into material savings and an ecological approach to production. Our plastic details are used in the automotive, electronics and industrial sectors, guaranteeing reliability, resistance and perfect adaptation to specific customer needs.

Plastic injection molding machines:

  • Arburg Allrounder 375V: vertical injection molding machine
  • Arburg Allrounder 470C: vertical injection molding machine

 

Forming plastic parts – plastic injection

Forming plastic parts – plastic injection  is a modern method of producing precise elements that allows for the creation of durable, aesthetic and repeatable components. Thanks to injection technology, we can produce both small and large series of parts with complex shapes that meet the highest quality requirements.

We have advanced machinery park that provides precision, high efficiency and waste minimization, which translates into material savings and an ecological approach to production. Our plastic details are used in the automotive, electronics and industrial sectors, guaranteeing  reliability, resilience and perfect adaptation to specific customer needs.

Plastic injection molding machines:

  • Arburg Allrounder 375V: vertical injection molding machine
  • Arburg Allrounder 470C: vertical injection molding machine

Harness assembly

The assembly of cable harnesses is the final stage of the production process, in which all previously prepared components are assembled into a finished product. It involves the proper arrangement and connection of cables, connectors and covers in accordance with the technical documentation and customer requirements. The whole is then subjected to quality control to ensure reliability and compliance with specific standards. Cable harnesses are made on special assembly boards and assembly and control tables dedicated to a specific type and customer.

Contact our wiring harness production department

+48 41 273 81 20

biuro@starpol.pl