Cable assembly, electronics manufacturing and assembly as an extended workbench for custom solutions and small series
elco GmbH
Haßfurt · Flugplatzstr. 18New on Amplifa
About elco GmbH
elco GmbH is a cable assembly company based in Haßfurt (Bavaria). The company manufactures cable sets to customer specification, from cutting to length, stripping and contact crimping through to cable printing via inkjet. In addition, elco GmbH realizes complete electronics projects: PCB development (schematic and layout), population, module assembly and calibration of electronic assemblies. As a so-called extended workbench, the company carries out assembly and testing work on mechanical and electronic devices, among other things for customers from the medical sector; another area of activity is grid assembly for wide-area luminaires. Using a CNC gantry milling machine (working area 1,800 x 1,200 mm), large-format milling projects such as aluminium fronts and housings are machined, and an in-house design department covers tool and fixture making. The focus is on custom solutions and small series within a full product range around cables and wires. The company is certified to ISO 9001:2015 and employs 41 staff members.
- Site
- Haßfurt
- Processes
- Cable assembly, Electronics development (schematic, layout), Population and module assembly (electronic assemblies), Calibration of electronic assemblies, Assembly work on mechanical and electronic devices, Testing work / final inspection, CNC milling (PCB/milled parts, aluminium fronts, housings), Crimping (contact/cable lug crimping)
- Materials
- Aluminium, Strands/cables from 0.50 mm² cross-section, Cable cross-sections 6 mm² to 240 mm², Copper (conductor material), Cables and wires from 0.50 mm²
- Certificates
- ISO 9001:2015
- Founded
- 1993 (Comp
- Employees
- 41
- Industries
- Medical technology, Automotive/Motorcycles (exhaust flap control for Harley), Luminaire manufacturing (grid assembly for wide-area luminaires)
- 01
Electronics development (schematic, layout)
- 02
PCB development
- 03
Cable assembly (cutting to length, stripping, crimping)
- 04
Cable printing
- 05
Module population and assembly
- 06
Calibration and final inspection
Materials and Processes
Aluminium
Machining of large-format aluminium fronts and housings on the CNC gantry milling machine.
Copper (conductor material)
Processing of cables, strands and compression cable lugs from 6 mm² to 240 mm² during crimping.
Cables and wires from 0.50 mm²
Full product range around cables and wires, printing of strands from 0.50 mm² cross-section.
Locations
Haßfurt
DEProduction and administration
- Lot size
- Custom solutions, small series
- Materials
- Cables, wires, aluminium
- CNC gantry milling machine (1,800 x 1,200 mm)
- Crimp full-automatic machine (cutting to length, stripping, contact crimping)
- Crimp semi-automatic machines HD 20 / HD 22
- Hydraulic press (compression cable lugs 6–240 mm²)
- Electric presses (flat tab connectors, ring cable lugs, ferrules, claw cable lugs)
- Hand crimping tools (MNL, M III, RJ 45, MODU IV)
- Stripping box
- Cutting machine
- Solder baths and soldering stations
- Inkjet printers for cable printing
- Shaping devices for flat ribbon cables
- Knee-lever presses for IDC connectors
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assemblyAssembly | – | – | – | – | Cables, Wires |
| Electronics development (schematic, layout)Engineering | – | – | – | – | – |
| Population and module assembly (electronic assemblies)Assembly | – | – | – | – | – |
| Calibration of electronic assembliesTesting | – | – | – | – | – |
| Assembly work on mechanical and electronic devicesAssembly | – | – | – | – | – |
| Testing work / final inspectionTesting | – | – | – | – | – |
| CNC milling (PCB/milled parts, aluminium fronts, housings)Machining | – | 1,200 mm | – | – | Aluminium |
| Crimping (contact/cable lug crimping)Joining | – | – | – | – | Copper |
| Cutting to length, stripping and crimping (full-automatic, in one step)Assembly | – | – | – | – | Wires |
| Soldering (soldered joints)Joining | – | – | – | – | – |
| Cable printing (inkjet)Surface | – | – | – | – | Cables, Strands from 0.50 mm² cross-section, Housings, Connector caps |
| Tool and fixture making (design department)Engineering | – | – | – | – | – |
| Grid assembly for wide-area luminairesAssembly | – | – | – | – | – |
| PCB developmentEngineering | – | – | – | – | – |
| Processing of compression cable lugs 6 mm² to 240 mm²Joining | – | – | – | – | Copper |
| IDC termination processing (flat ribbon cables, knee-lever presses)Joining | – | – | – | – | Wires |
12 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC gantry milling machine | – | – | 1,800 mm x 1,200 mm | – | Haßfurt |
| Hydraulic press | – | – | Compression cable lug dies 6 mm² to 240 mm² | – | Haßfurt |
| Crimp full-automatic machine | – | – | Cutting to length, stripping and contact crimping in one step | 2007 | Haßfurt |
| Crimp semi-automatic machine | HD 20 / HD 22 contact dies, flat tab connector, ring cable lug, | – | – | – | Haßfurt |
| Stripping box | – | – | – | – | Haßfurt |
| Hand crimping tools | MNL, M III, RJ 45, MODU IV | – | – | – | Haßfurt |
| Electric presses | Flat tab connector, ring cable lug, ferrule, claw cable lug dies | – | – | – | Haßfurt |
| Solder baths and soldering stations | – | – | – | – | Haßfurt |
| Cutting machine | – | – | – | – | Haßfurt |
| Inkjet printer (cable printing) | – | – | Cables, strands from 0.50 mm², housings, connector caps | 2007 | Haßfurt |
| Shaping devices (round to flat ribbon cables) | – | – | – | – | Haßfurt |
| Knee-lever presses (IDC connectors) | – | – | – | – | Haßfurt |
Additional services
Quality
A documented quality management system covers the development, production and distribution of cable sets and assemblies; the processes are continuously monitored and improved. Final inspection of products is also offered.
| Evidence | Haßfurt |
|---|---|
| ISO 9001:2015 |
History
- 1993
Company founded in Haßfurt (PCB development, cable assembly as a subcontractor)
- 1996
Converted into a GmbH, establishment of own sales operation
- 2001
Design department for tool and fixture making, expansion of the range of services
- 2004
Relocation of company headquarters to Königsberg, expansion of production and office space to 1,000 m²
- 2005
Entry into grid assembly for wide-area luminaires
- 2006
Certification to DIN EN ISO 9001:2000
- 2007
Expansion of the machine park: cable printing with inkjet printer, full-automatic machine for cutting to length, stripping and contact crimping
- 2015
Purchase of the company site in Haßfurt and renovation of the 1,800 m² building, relocation from Königsberg to Haßfurt