Our Approach
Software-integrated manufacturing that turns the traditional harness procurement process from weeks into days.
The problem we're solving
The traditional wire harness procurement process hasn't changed in decades. You email a PDF to a manufacturer. They take 7 to 10 business days to return a quote, if they respond at all. You iterate on the design through phone calls and revised attachments. Nobody has a single source of truth for the current revision.
We built our approach around eliminating every one of these failure modes: a digital design platform that serves as the single source of truth, instant quoting that removes the back-and-forth, and automated work instructions that ensure your harness is built exactly as designed.
Industry average to return a wire harness quote. With Cabelio, it takes minutes.
Powered by Cabelio
We designed and built Cabelio, a free, web-based harness design tool, and we use it internally to power our manufacturing operations. Our customers use the same platform to design, quote, and track their orders.
Interactive harness design
Cabelio replaces the back-and-forth of emailing PDFs with an interactive design tool. Customers map connectors and pins visually, define wire properties, add bundling and overwrap, and write build notes, all in the browser. No CAD experience required.
Every design includes full revision history and team approval workflows. When a design is approved, it locks, so the version that goes to production is always the version you signed off on.
Instant, transparent quoting
The industry average for a wire harness quote is 7 to 10 business days. In Cabelio, you see itemized pricing the moment your design is complete. Materials, labor, testing and every line item is visible.
Choose from multiple manufacturing tiers based on your timeline and budget. No phone calls, no email chains, no waiting.
Automated work instructions
Every approved harness design automatically generates step-by-step production instructions for our technicians. Wire-by-wire routing, connector loading sequences, bundling specifications. Nothing is left to interpretation.
This eliminates the tribal knowledge problem that plagues traditional harness shops, where build quality depends on which technician happens to be at the bench. Your harness is built the same way every time, regardless of who builds it.
Our process
Six steps from design submission to delivered harnesses. Typical lead time is 3 to 10 business days with materials on hand.
Design & Submit
Create your harness design in Cabelio, our free web-based platform, or upload an existing drawing, sketch, or BOM. The platform validates your design and generates a quote instantly.
Engineering Review
Our engineering team reviews every submission for manufacturability. You'll receive DFM feedback within 24 to 48 hours, including recommendations on connector selection, wire routing, and cost optimization.
Material Procurement
We source components from our approved vendor list or your specified suppliers. Every incoming component undergoes inspection before entering production. Long-lead items are flagged early.
Production
Automated wire processing handles cutting, stripping, and marking at up to 2,000 wires per hour. Skilled technicians perform crimping, soldering, assembly, and connector loading on custom formboards.
Test & Inspect
100% electrical testing on every harness, including continuity, isolation, and hi-pot where applicable. Visual inspection under magnification per IPC/WHMA-A-620 Class 3. First-article inspection on new part numbers.
Ship & Deliver
Finished harnesses are packaged with full documentation: certificate of conformance, test data, and revision records. You're notified via the Cabelio platform when your order ships.
Quality is not an add-on
We manufacture every harness to IPC/WHMA-A-620 Class 3, the highest workmanship standard for cable and wire harness assemblies. This is not an optional tier or a premium surcharge. It is our production baseline.
Our quality program is led by Guy Kemp, whose IPC inspection and production management experience spans Bell Helicopter, SpaceX, and Blue Origin. Every harness undergoes 100% electrical testing (no statistical sampling), visual inspection under magnification at the applicable IPC class level, and first-article inspection on all new part numbers. All results are logged digitally with serial-number traceability.
We are pursuing AS9100 Rev. D aerospace quality management system certification, with a target completion within 12 to 18 months. ITAR registration is in process to support defense and export-controlled programs.