Cable assembly
Tailored. Innovative. Individual.
Industry-specific
Cable assembly. Together
Developed. Works perfectly.
In modern electromechanics, reliable connections are crucial for the performance, stability, and unimpaired function of your assemblies and systems. For over 95 years, Püplichhuisen has stood for quality in electromechanical connection technology and understands the demands of a wide variety of industries – from mechanical engineering and automotive to medical technology. It is precisely this understanding that flows into every customised solution.
In our cable assembly facility, we manufacture and assemble your cable harnesses and assemblies – developed in collaboration with you, manufactured to your standards and delivered on time. Consultancy, design, procurement, production, quality assurance and logistics work together seamlessly. The result is a cable assembly that is technically sound, cost-optimised and tailored to your application and industry (including UL approval).
Through the combination of manual and fully automated production, we remain flexible, efficient, and reliable in series.
Was ist Kabelkonfektionierung?
Cable assembly refers to the professional processing and assembly of cables into ready-to-use connection solutions. In this process, cables are precisely cut to the desired length, stripped, and fitted with various connection elements such as connectors, terminals, or soldered connections in cable processing.
The process involves far more than simply attaching connectors. Modern cable assembly requires a deep understanding of material sciences, electrical properties, and mechanical stresses. Each cable assembly is individually tailored to the specific requirements of the application – from selecting the optimal cable material to choosing the appropriate connection technology.
At Püplichhuisen, we regard cable assembly as an engineering discipline. Our experts carry out a comprehensive analysis of your requirements and develop solutions that not only work today, but will also meet future challenges.
Our services in the
Cable assembly⁺.
Application advice
What challenges are you facing? In a personal consultation, we will analyse your application with you and advise you on technical, manufacturing-optimised, and commercial solution options. If you wish, our employees will visit your company on-site and develop an individual concept together with you.
Customer service
Does our solution meet your requirements? Despite the use of a wide range of automated processes, a cable harness is largely manufactured by hand. We would therefore be happy to produce your specific approval sample or prototypes in advance for your approval.
Professional
Wiring harness design
Procurement and Materials Management
How can your complex product be realised? Trust in our global network: Through our production experience and long-standing manufacturer contacts in the field of electromechanics, we can procure and store your components for you and advise you on sensible alternatives and allocation management.
Quality Assurance and Certifications
DIN EN ISO 9001:2015, DIN EN ISO 14001:2015, UL Wiring Harness E-File E317941, UL Processed Wire E-File E338687, pull-out test DIN EN 60352-2, micrograph laboratory, 100 % test (optical/electrical), initial sample test report
Production
Mit unserem breiten Spektrum bei der Produktion von Kabelsätzen und Baugruppen bieten wir Ihnen sowohl Handmontage, halbautomatische Fertigung als auch Vollautomatisierung. Dabei vereinen wir u.a. folgende Techniken unter einem Dach: Crimptechnik, Löttechnik, Kennzeichnungstechnik, Splicetechnik, Presstechnik, Verguss 1K/2K Schrumpftechnik, Montagetechnik, Niederdruckguss (HotMelt).
Packaging and Logistics
- AEO certified
- Bespoke packaging
- Customised printing/labelling
Special solutions within
cable assembly.
Wiring harness production
We plan wiring harnesses with millimetre precision: cable routing, bending radii, strain relief, labelling and connector systems are tailored to your installation situation. Approval samples ensure the perfect fit before series production – this reduces assembly times and minimises failure risks from plant engineering to device and mechanical engineering.
Assembly
Complete assemblies for machinery, equipment and building services – tested, labelled and ready for immediate installation. Transparent processes, traceable test reports and consolidated deliveries make integration into your production process easier. You save time, reduce effort and keep deadlines and quality under control.
Manufacturing technologies within
cable assembly.
Our semi- and fully automated production lines ensure the highest precision and reproducibility.
We are experts in all modern joining technologies and select the best method for every application:
Crimping technique
Soldering technique
Splicing technology
Shrink-wrapping technology
Assembly technology
Labelling technology
IDC Technology
1K / 2K casting compound
Sektoren und
Areas of application.
Whether it’s a high-voltage cable assembly, a delicate medical cable or a maritime SHF2 solution – we develop and manufacture customised connections for virtually any application. Benefit from our many years of industry expertise, certified processes and state-of-the-art testing technology, ensuring your products function reliably worldwide. We are particularly strong in the following markets:
Technical standards and specifications.
Efficient processes and uncompromising quality are the foundation of our cable assembly. To ensure your products can be approved smoothly worldwide, transported safely, and used faultlessly, we comply with a broad spectrum of packaging, logistics, and testing standards.
Packaging & Logistics
- AEO-certified customs and security status
- Customised packaging solutions
- Customised printing / labelling
Quality Assurance & Certifications
- DIN EN ISO 9001:2015 (Quality Management)
- DIN EN ISO 14001:2015 (Environmental management)
- UL Wiring Harness – E-File E317941
- UL Processed Wire – E-File E338687
- Pull-off test according to DIN EN 60352-2
- Microstructural analysis laboratory for the analysis of crimped and soldered joints
- 100 % optical and electrical final inspection
- First Article Inspection Report (EMPB) in accordance with VDA/PPAP
The benefits you’ll enjoy with
Cable assembly by
Püplichhuisen.
Over 40 years of experience in cable assembly
We develop connection solutions and have over 40 years’ experience in cable assembly. We combine this long-standing tradition with state-of-the-art technology and continuous innovation. Our wealth of experience enables us to find the optimal solution, even for unusual requirements.
Optimised total costs through fewer interfaces
We take over the purchasing and service management in the areas of administration, procurement, production and logistics for you. This saves you time and costs in coordinating your project and frees up your resources.
Flexibility from prototype to mass production
Whether you need a single prototype or thousands of cable assemblies – we adapt our manufacturing processes flexibly to meet your requirements. Our modular production systems enable both cost-effective small-batch production and highly automated large-scale production.
Hand in Hand: Distribution & Cable Assembly
The distribution division and the cable assembly division of Karl Püplichhuisen GmbH & Co. KG share valuable resources. Thanks to the existing structures, you benefit from ongoing stock management and availability of materials, as well as a rapid flow of information.
Now customise
Request a cable assembly!
Do you have any specific requirements, or do you need a bespoke cable assembly? Please use our contact form or call us directly to find out more about our distribution services. Our engineers will analyse your requirements and provide you with a detailed quotation.
Karl Püplichhuisen – Your trusted partner for the distribution of electromechanical products and cable assembly since 1926. Quality, innovation and service, all from a single source.
FAQ: Frequently Asked Questions for cable assembly.
What is cable assembly and what are its benefits?
Cable assembly refers to the professional processing of cables by cutting, stripping, crimping, soldering, and fitting connectors. Assembled cables offer significant advantages over standard cables: precise lengths, optimised connections, reduced assembly time for the customer, and increased reliability due to professional manufacturing.
What types of cables can be terminated?
Virtually all common types of cable can be assembled: data cables (USB, Ethernet, coaxial cables), power cables (mains cables, high-current cables up to 1000 A), signal cables (audio, video, sensor), special-purpose cables (fibre-optic, high-frequency, high-temperature), ribbon cables, round cables and hybrid cables. From thin 0.1 mm² signal wires to thick high-current cables with a cross-section of 240 mm², we process all standard conductor cross-sections.
What connectors and terminals are available for cable assembly?
Our product range includes over 10,000 different connectors: D-Sub, USB, RJ45, RCA, XLR, DIN, M8/M12 circular connectors, Phoenix Contact, Wago, Molex, JST, Hirose, and many more. We process crimp contacts, solder connections, screw terminals, and spring clamp terminals. Customised or obsolete connectors can often also be sourced and processed.
Can special materials and specialist cables also be processed?
Yes, we process special materials such as PTFE (Teflon), FEP, silicone, TPE, polyurethane, and halogen-free materials. We also offer high-temperature cables up to 200°C, chemical-resistant cables, UV-resistant outdoor cables, oil-resistant cables, and flame-retardant materials according to UL94.
Which certifications and standards are met?
Our cable sets are produced under DIN EN ISO 9001:2015 and 14001:2015 certified processes. Each assembly is tested for continuity, contact resistance, and insulation (up to 5,000 V), then subjected to a high-voltage and tensile test in accordance with DIN EN 60352-2 and analysed in the cross-section laboratory.
What delivery options and packaging are available?
We offer flexible delivery options: standard shipping, express delivery, call-off orders, and just-in-time delivery. Packaging options range from standard cartons to antistatic packaging and bespoke packaging solutions. Labelling to customer specifications, barcode labels, and tracking systems optimise your logistics processes.