Lead wires form an electrical connection between two electronic/electrical contacts. Applications include automobiles, controls panels, appliances, motors, generators, printers, switchgear, and medical devices – just to name a few. For product designers, lead wire selection begins by understanding all of your application requirements. Yet designers also need lead wire assembly services that are fast, accurate, and cost-effective. At SHINE, we’re ready to support your custom cable assembly projects at every step of the way.

Lead Wire Selection

Lead wires consist of one copper conductor, solid or stranded, that’s jacketed by insulation. Commonly used insulation materials include EPDM, PTFE, PVC, Silicone, Neoprene, and Hypalon. In addition to meeting specific thermal, mechanical, and electrical requirements, your lead wire application may require compliance with standards from UL and CSA.

Specifications for lead wires also include gauge size, voltage, stranding, jacket material, maximum temperature, and color. As an experienced custom cable assembly manufacturer, SHINE offers engineering support that includes design assistance and help with lead wire selection. So whether you need silicone rubber lead wires for high-temperature, high-voltage applications like motors, or hookup wires for low voltage, low current applications in electronics, SHINE is ready and able to help.

Lead Wire Assembly

Lead wire assembly at SHINE combines the power of a highly-trained workforce with state-of-the-art technology. The fully-automatic lead making equipment that we use provides greater consistency than either hand crimping or semi-automatic operations. Plus, unlike hand tools or benchtop equipment, fully-automated crimp processing incorporates wire cutting and wire stripping for manufacturing efficiency.

SHINE uses the Schaefer Megomat UNO Lead Maker for automated lead wire assembly. This six-station equipment features air-glide press bases for full access during quick setups. The machine’s open architecture also supports a wide range of processing tools. SHINE’s automated lead assembly equipment is capable of high-speed wire cutting, wire stripping, and lead termination on most typical wires and wire AWGs. Along with single-ended and double-ended cutting, features include crimp quality validation.

Choose Lead Wire Assembly Services from SHINE

SHINE is a manufacturer of custom cable assemblies that’s like an extension of your engineering department. From assistance with lead wire selection to high-quality lead wire assembly, we’re ready to support your projects. For more information, contact us at our manufacturing center in Adams, Massachusetts. At our website, you can also get a quote on-line.