Wire end processing
We select termination technology according to electrical and mechanical requirements: crimping, tinning and soldering, ultrasonic welding, and IDC connectors.
We work on mechanical, pneumatic and hydraulic presses, with clamping force analysis – from prototypes to high-volume series.
Selection of termination technology according to project requirements
Depending on the geometry of the joint, the cross-section of the cable and the durability requirements, we select the appropriate method: crimping, soldering or welding. We verify each process metrologically – from checking the crimping force to testing the connections.
For single series and prototypes, we use hand tools and semi-automatic machines, for mass production – pneumatic and hydraulic presses, and for low resistance and high durability requirements – ultrasonic welding.
- Cross-sections up to 300 mm² (hydraulic presses)
- Clamping force analysis and process quality sensors
- A complete set of applicators for various terminals
BRANCHES OF THE PROCESS
Shrinking
Mechanical, pneumatic and hydraulic presses; clamping force control; applicators for many types of tips.
Whitewashing and soldering
Preparation of terminals for assembly and permanent soldered connections – crucibles, ERS soldering stations.
Welding the joint
Ultrasonic wire bonding: low resistance, high durability – Branson 2032S, Sonobond WS 2026.
IDC connectors
Connections without stripping – quick and economical for ribbon and multi-core cables.
The machinery and processes we utilise
How we process cable ends
Presses and applicators
Presses and applicators for crimping
We use mechanical, pneumatic and hydraulic presses with a wide range of applicators.
For joints with large cross-sections and high forces required – hydraulic solutions with interchangeable dies.
Each process can be equipped with clamping force analysis.
Whitewashing and soldering
Whitewashing and soldering
Tinning prepares cable ends for further assembly, preventing strand separation and oxidation.
We also perform soldered connections in accordance with application requirements. We use hand soldering irons and
ERS soldering stations.
IDC
IDC connectors
IDC (Insulation Displacement Connection) does not require pre-stripping – during crimping, the insulation is displaced,
and electrical contact is established directly on the conductor. A quick and economical solution for ribbon cables
and multi-core harnesses.
Models
Models used at workstations
In various configurations, we use, among others, WDT UP 35, WDT SSC-2 FP,
Wirmec WSC 15, P-BHD-400, AH-400 / AH-400 F3,
T-12, 3K/40, 964 and P-100, as well as Lumberg IDC hand tools.
WHEN TO CHOOSE WHICH METHOD?
Crimp
Most commonly chosen for serial production. High speed, repeatability and process control (clamping force, geometry). Good mechanical resistance.
Solder
Good for prototypes and single-unit tasks. Ensures reliable electrical contact; requires thermal control and appropriate solder pad geometry.
Ultrasonic welding
Low resistance and high connection durability. Recommended for demanding applications and larger cross-sections/connection strips.
Quality control of end machining
We verify each connection in terms of dimensions, mechanical stability and electrical parameters. The use of clamping force analysers and weld parameter monitoring allows us to eliminate defects in real time.
Visual inspection of insulation
Clamping force analysis and crush geometry
Analysis of force and moment
Check out our certificates.
Related stages of the production process
Cutting and processing of cables
Preparing cables for termination: cutting, stripping, marking.
Machines for multi-core cables
Removal of the sheath and programmed isolation of the veins.
Injection moulding
Insulating elements, bushings, covers – protection for connections and components.
Let us handle this process for you.
Take advantage of our offer covering this stage of production and receive full technological support.
Cable connection services
Select the connection technology: crimp, solder, weld or IDC – according to your project requirements.
Get in touch with us
Do you need to select the right cable termination technology?
We will prepare a process recommendation (crimp, solder, weld, IDC) and workstation configuration tailored to your requirements.