Prototyping for wiring harnesses and cable sets
Quickly to the sample. Safely into series production.
- to small series
- Single piece
- changes integrated
- Fast
- transition into series production
- Seamless
Overview
Quickly to the sample. Safely into series production.
Flexible production structures let us produce prototypes and pre-series just as economically as recurring series orders. Changes during the development phase can be integrated quickly.
This shortens development times and speeds up market launches, with a single point of contact from the first idea to series production.
Scope of services
Prototyping at Powertune: what is included.
- Sample and prototype production
- Pre-series and small series
- Development and test projects
- Product adaptations and optimisations
- Series ramp-up and scaling of production
- Wiring harnesses to drawing or sample
Early samples that can later be carried over seamlessly into series production.
Examples
From our production.
Samples
Quickly to the first sample.
A sample should show early on whether the wiring harness and the installation situation fit together. That calls for short routes: at Powertune, design, material procurement and production sit under one roof. Changes from the first installation go straight into the drawing and into production.
For samples and small lots we use semi-automatic machines with short setup times: the Komax Delta 260 and the Schäfer SealLine 240-1 ADVANCED strip the cable, set the single wire seal and crimp in one operation. Stripping tasks are handled by the Komax Mira 230, among others.
Pre-series
From sample to series production without a break.
We produce samples with the same processes, contacts and tests as the later series. Single pieces too are made with monitored crimping and tested electrically. What proves itself in the sample we carry over into pre-series and series production.
- Samples and single pieces
- Pre-series and small series for tests and trials
- Adaptations after testing and installation
- Series ramp-up with released documentation
Changes
Plan for changes instead of fearing them.
During development something almost always changes: a different connector, a longer cable, an additional sensor. We document every revision, so that sample, drawing and later series match and you know at any time which revision is installed.
FAQ
Frequently asked questions.
Do you also produce small series or prototypes?
Yes. Alongside series production, Powertune produces prototypes, single pieces, pre-series and small series. Adaptations are implemented, tested and optimised quickly before series production starts.
How quickly do I get a sample?
That depends on the scope and on the availability of the components. Short routes between design, purchasing and production let us produce samples quickly. Tell us your target date in the enquiry. We will give you a firm answer on what is possible.
Are samples tested in the same way as series parts?
Yes. Samples and single pieces are also made with monitored crimping and tested electrically. On request you receive the test report with the delivery.
What happens if a connector is not available?
We propose equivalent alternatives and agree them with you before we produce. That keeps the date for the sample realistic, without compromising the technical requirements.
Can the sample go straight into series production?
Yes. Samples are made with the same processes as the series. Once you have released them, we carry the drawing, the bill of materials and the scope of testing over into series production.
Request a quote
Let us talk about your project.
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will get back to you with a non-binding quote.
More services
Everything from a single source.
Cable assemblyReady to install cables, cable sets and wiring harnesses
Wiring harness manufacturingWiring harnesses to drawing, sample or 3D data
Development & designCAD design with EPLAN, documentation to PPAP
Series productionFully automatic cable processing machines, MES controlled and traceable
Testing & documentationProcess monitoring, electrical final testing, test recordsIndustry solutionsTo the overview