Manufacturing and development of cable harnesses and cable sets from prototype to series production.
Appinger Kabelsysteme GmbH
94436 Haunersdorf (Headquarters, Production, Administration)New on Amplifa
About Appinger Kabelsysteme
Appinger Kabelsysteme GmbH, based in Haunersdorf in Lower Bavaria, is a specialist in cable assembly. The company manufactures and develops wiring systems ranging from individual wires to coaxial, flat ribbon, jacketed and spiral cables through to complex vehicle cable sets – with a documented maximum of over 700 individual wires and nearly 200 connector contacts per cable set. Wires from 0.13 mm² to 120 mm² are processed, as well as ISOBUS, CAN bus and energy chain cables; the processes include crimping, IDC insulation displacement technology, braiding, twisting, taping, ultrasonic welding and inkjet printing. In addition, the company offers electrical and vehicle electrical system planning using Aucotec Engineering Base / EB Cable, 3D CAD design with Solid Edge, 3D printing of production aids, as well as prototype, sample and small-series builds. Key industries are special-purpose vehicle and machinery construction as well as agricultural technology, commercial vehicles, electronics, building services and electrical installations. The GmbH, founded in 2015, emerged from Erich Appinger KFZ-Elektrik, active in cable assembly since 1984; the products are now used worldwide.
- Site
- Haunersdorf
- Processes
- Cable assembly / cable harness manufacturing (prototype to series production), Cable sets / wiring sets (complex cable harnesses, over 700 individual wires, nearly 200 connector, Crimping (crimp contacts, board-in contacts, ferrules, tinned wire ends, cable lugs), IDC insulation displacement technology, Individual wire sealing, Inkjet printing / wire marking (from approx. 0.5 mm²), Marking, Braiding
- Materials
- Wires (copper), Coaxial cables, Flat ribbon cables, Jacketed cables, Spiral cables, Battery connection cables up to 120 mm², Energy chain cables, ISOBUS and CAN bus cables
- Certificates
- ISO 9001:2015, ISO 9001
- Founded
- 2015
- Industries
- Special-purpose vehicle construction, Mechanical and plant engineering, Agricultural technology, Commercial vehicles, Bus manufacturing, Electronics
- 01
Electrical / vehicle electrical system planning
- 02
3D CAD design
- 03
Material selection
- 04
Prototype / sample build
- 05
Cable assembly (crimping, printing, braiding, taping)
- 06
Electronic function testing
- 07
Assembly
- 08
Logistics
Materials and Processes
Copper wires 0.13–120 mm²
Base material for individual wires, battery connection cables up to 120 mm² and complex cable sets.
Coaxial cables
Used in audio, video, measurement technology and HV cable sets.
Flat ribbon cables
Cost-effective solution for high-pin-count connections of electronic components.
Jacketed cables
Optimal cable protection for cables in motion during operation.
Spiral cables
Used in vehicle construction and on movable equipment.
ISOBUS and CAN bus cables
For networked systems in agricultural technology and commercial vehicles.
Energy chain cables
For moving parts in mechanical and plant engineering, including selection, dimensioning and assembly.
Battery connection cables up to 120 mm²
For high-current applications, including battery terminal contacts and fuse elements.
Locations
Haunersdorf
DEHeadquarters, Production, Administration
- Lot size
- Single pieces to series production
- Materials
- Copper wires, coaxial, flat ribbon, jacketed and spiral cables, ISOBUS/CAN, energy chain cables
- Fully automatic crimping machine (2018, upgraded in 2021)
- Taping machine (2021)
- over 130 tools for crimp contacts
- Hand tools
- Ultrasonic welding
- Aucotec Engineering Base / EB Cable
- Solid Edge
- 3D printer
- Inkjet printing
- Electronic function test systems
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly / cable harness manufacturing (prototype to series production)Joining | – | – | – | Single pieces – Series production | Wires 0.13 mm² to 120 mm², Coaxial cables, Flat ribbon cables, Jacketed cables, Spiral cables, Battery connection cables up to 120 mm², Energy chain cables, ISOBUS and CAN bus cables |
| Cable sets / wiring sets (complex cable harnesses, over 700 individual wires, nearly 200 connectorJoining | – | – | – | – | – |
| Crimping (crimp contacts, board-in contacts, ferrules, tinned wire ends, cable lugs)Joining | – | – | – | – | – |
| IDC insulation displacement technologyJoining | – | – | – | – | – |
| Individual wire sealingSurface | – | – | – | – | – |
| Inkjet printing / wire marking (from approx. 0.5 mm²)Surface | – | – | – | – | – |
| MarkingSurface | – | – | – | – | – |
| BraidingJoining | – | – | – | – | – |
| TwistingJoining | – | – | – | – | – |
| Taping / cable protectionAssembly | – | – | – | – | – |
| Ultrasonic weldingJoining | – | – | – | – | – |
| Coaxial cables / HV cable setJoining | – | – | – | – | Coaxial cables |
| Electronic function testingTesting | – | – | – | – | – |
| Housing machiningMachining | – | – | – | – | – |
| 3D printing (custom aids)Additive | – | – | – | – | – |
| Electrical planning / system circuit diagrams, wiring diagrams, bills of materialsEngineering | – | – | – | – | – |
| Vehicle electrical system planning (Aucotec EB Cable)Engineering | – | – | – | – | – |
| 3D CAD design (Solid Edge)Engineering | – | – | – | – | – |
| Customizing / special cable harnessesJoining | – | – | – | – | – |
| Development support / material selectionEngineering | – | – | – | – | – |
| Prototypes, small series, sample buildsJoining | – | – | – | – | – |
| Electronic modules with development partnersAssembly | – | – | – | – | – |
| Assembly of energy chain cables, charging cables, ground connection cablesAssembly | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Fully automatic crimping machine | – | – | – | 2018 (aufg | Haunersdorf |
| Taping machine | – | – | – | 2021 | Haunersdorf |
| Over 130 tools for various crimp contacts | – | – | – | – | Haunersdorf |
| Hand tools | – | – | – | – | Haunersdorf |
| Electrical engineering software Aucotec Engineering Base / EB Cable | Aucotec Engineering Base / EB Cable | – | – | – | Haunersdorf |
| 3D CAD system Solid Edge | Siemens Solid Edge | – | – | – | Haunersdorf |
| 3D printer | – | – | – | – | Haunersdorf |
Additional services
Reference customers
Quality
The company is certified according to ISO 9001:2015; all processes are defined, continuously reviewed and monitored annually. Production takes place entirely in-house, ensuring compliance with quality standards; the electronic function is tested as a final step.
| Evidence | Haunersdorf |
|---|---|
| ISO 9001 |
History
- 1984
Erich Appinger is entrusted by Neoplan with initial work in circuit wiring.
- 1994
First successful projects with complete cable sets for buses.
- 2003
Product portfolio expanded to include complete cable sets for the agricultural sector.
- 2009
Thomas Appinger takes over management of the cable assembly business unit.
- 2011
Circuits and control technology complement the product range.
- 2013
Products for mechanical and plant engineering added to the range.
- 2015
Founding of Appinger Kabelsysteme GmbH as a spin-off of Erich Appinger KFZ-Elektrik under Managing Director Thomas Appinger; move into a newly built office.
- 2017
Expansion of production and storage space as well as the machine park.
- 2018
Verena Appinger becomes a member of the management board; expansion of the product portfolio and acquisition of a fully automatic crimping machine.
- 2021
Expansion of the machine park: taping machine and upgrade of the fully automatic crimping machine.
- 2025
10 years of successful company history.