Manufacture of electromechanical assemblies, cable assembly, HotMelt encapsulation and FDM 3D printing to customer specification.
rmw Kabelsysteme GmbH
Crossen an der Elster (Site I – Management and Production) · Hartmannsdorf (Site II – Aerospace Production) · Crossen an der Elster (Site III – Sales)New on Amplifa
Creating connections – for three decades
rmw Kabelsysteme GmbH was founded in 1991 as a spin-off of the Carl Zeiss Jena Group and manufactures demanding electromechanical assemblies, complete systems and customer-specific cable assemblies for machinery and equipment manufacturing, medical technology, aerospace and Defense & Security. At the main site in Crossen an der Elster (5,000 m² of production and 2,200 m² of warehouse space incl. storage shuttle) and at the Hartmannsdorf site, the center for aerospace production, the company produces to customer specifications, among other things, control cabinet wiring, complete system cabling (EWIS), X-ray generator cabling with harnesses up to 36 meters long, and assemblies for cockpits and aircraft seats. The manufacturing portfolio includes cutting and stripping with Schleuniger semi-automatic machines, laser-based stripping with CO2 and UV lasers, crimping from 0.05 to 70 mm², soldering to IPC standards at ESD workstations, various marking methods, HotMelt encapsulation using low-pressure injection molding, and FDM 3D printing for prototypes and jigs. All products undergo 100% electrical and visual inspection; in addition, the company offers design support services from drawing creation in Solid Edge through to series production transfer. Around 200 employees manufacture more than 1,000,000 assemblies per year for almost 150 active customers worldwide.
- Site
- Crossen an der Elster
- Processes
- Cable assembly (cutting, stripping, crimping, soldering), Laser-based stripping (CO2 laser, UV laser), Crimping, Soldering to IPC standards, Cable marking (inkjet printing, UV laser, thermal transfer/thermal direct printing,, Electrical and visual testing (connection, short-circuit, insulation,, FDM 3D printing, HotMelt encapsulation (low-pressure injection molding)
- Materials
- PLA, Nylon, TPU, CPE, ASA, PVA (support filament), Thermoplastic high-performance polyamides (HotMelt), All types of cable raw material
- Certificates
- ISO 9001, DIN EN 9100/AS9100, UL, FAI per EN 9102, EN 9100 (Aerospace)
- Founded
- 1991
- Employees
- approx. 200
- Industries
- Machinery & Equipment Manufacturing, Medical Technology & Life Science, Aerospace & Space, Defense & Security
- 01
Engineering and design (Solid Edge)
- 02
Prototype manufacturing / FDM 3D printing
- 03
Material procurement
- 04
Cable cutting and stripping
- 05
Crimping / soldering
- 06
Marking
- 07
HotMelt encapsulation
- 08
Assembly manufacturing and assembly
- 09
100% electrical and visual inspection
- 10
Delivery
Manufacturing portfolio and technologies
PLA
Environmentally friendly filament in various colors for prototypes and sample production in FDM 3D printing.
Nylon
Durable filament for robust 3D-printed components.
TPU
Flexible filament for elastic components in the FDM process.
CPE
Chemically resistant filament for demanding 3D printing applications.
ASA
Weather-resistant filament for components with outdoor requirements.
PVA (support filament)
Water-soluble support material for complex geometries with strong overhangs.
Thermoplastic high-performance polyamides (HotMelt)
Low-pressure injection molding process for encapsulating and protecting sensitive electrical components, operating range -40 °C to 130 °C, flammability rating UL94 V-0.
All types of cable raw material
Standard and special cables, including twisted shielded wires for laser-based stripping.
Locations
Crossen an der Elster
DESite I – Management and Production
- Lot size
- Prototype to small series
- Materials
- Cables, plastics, thermoplastic high-performance polyamides
- Cutting and stripping semi-automatic machines (Schleuniger)
- CO2 laser for stripping (Schleuniger)
- UV laser SYLADE 7 (Laselec)
- Cutting machines (Schleuniger)
- Semi-automatic press
- Pneumatic press
- FDM 3D printers
- Storage shuttle
Hartmannsdorf
DESite II – Center for Aerospace Production (2,800 m² production space)
- Materials
- Aerospace cables, shielded wires
Crossen an der Elster (Site III)
DESite III – Sales
Components and products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly (cutting, stripping, crimping, soldering)Joining | – | several hundred meters × 16 mm cable diameter | – | Prototype / lot size 1 – Small series | All types of cable raw material |
| Laser-based stripping (CO2 laser, UV laser)Joining | – | – | – | – | twisted shielded wires |
| CrimpingJoining | – | – | – | – | Copper, Conductor cross-sections from 0.05 mm² to 4 mm² |
| Soldering to IPC standardsJoining | – | – | – | – | Connectors, ESD-sensitive components |
| Cable marking (inkjet printing, UV laser, thermal transfer/thermal direct printing,Surface | – | – | – | – | Cables, Wires, Heat-shrink tubing, Labels |
| Electrical and visual testing (connection, short-circuit, insulation,Testing | – | – | – | – | electrical assemblies, Cables, Complete systems |
| FDM 3D printingAdditive | – | – | – | Prototype – Small series | PLA, Nylon, TPU, CPE, ASA, PVA (support filament) |
| HotMelt encapsulation (low-pressure injection molding)Plastics | – | – | – | Model – Large series | thermoplastic high-performance polyamides |
| Machining of HotMelt casting moldsMachining | – | – | – | – | – |
| Control cabinet wiring/assemblyAssembly | – | – | – | – | – |
| Assembly manufacturing and installationAssembly | – | – | – | Lot size 1 – Small and medium series | Temperature sensors, Sensor actuators |
| Electromechanical complete systems (system cabling, EWIS)Assembly | – | Harnesses up to 36 meters | – | Lot size 1 – Small series | Cables, Connectors, populated circuit boards, Relay and switch units, Electronic and mechanical parts |
| Design support (drawing creation in Solid Edge, production documentation, sample production,Engineering | – | – | – | – | – |
| Miniature mechanical manufacturingMachining | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Cutting and stripping semi-automatic machines | Schleuniger | – | – | – | Crossen an der Elster |
| CO2 laser for stripping | Schleuniger | – | – | – | Crossen an der Elster |
| UV laser for stripping and cable marking | Laselec SYLADE 7 | – | Conductor cross-sections 1/1000 to 16 mm² | – | Crossen an der Elster |
| Cutting machines | Schleuniger | – | – | – | Crossen an der Elster |
| Semi-automatic press (crimping up to 4 mm²) | – | – | – | – | – |
| Pneumatic press (crimping up to 70 mm²) | – | – | – | – | – |
| FDM 3D printers | – | – | – | – | Crossen an der Elster |
Additional services
Reference customers
Quality and certifications
All products undergo 100% electrical and visual inspection, including connection, short-circuit, insulation and dielectric strength tests, four-wire measurements, protective earth and functional tests. Test adapters for customer-specific assemblies are manufactured in-house; crimp quality is systematically monitored via cross-section analyses and pull-off tests.
| Evidence | Crossen an der Elster | Hartmannsdorf |
|---|---|---|
| ISO 9001 | ||
| EN 9100 (Aerospace) | ||
| UL | ||
| FAI per EN 9102 |
Milestones since 1991
- 1991
Foundation of rmw Kabelsysteme GmbH as a spin-off of the Carl Zeiss Jena Group
- 1993
Trade fair appearance Elektromechanika 93
- 1994
Initial certification by VDE to DIN ISO 9002
- 1996
First assemblies for customers from the medical technology sector
- 1998
Installation of the storage shuttle at site 1
- 2001
Contract signing with Airbus; start of the aerospace division
- 2003
Initial certification by DQS to EN 9100:2003; opening of site 3
- 2005
Expansion of aerospace production space to 1,400 m²
- 2006
20 years of rmw
- 2011
Doubling of aerospace production space to 2,800 m²
- 2012
25th anniversary and hiring of the 175th employee
- 2016
Dietmar Körner becomes Managing Director
- 2018
Introduction of a location detection system for tracking production orders
- 2019
New freight elevator; traceability via BDE numbers on articles
- 2020
Introduction of FDM 3D printing
- 2021
30 years of rmw Kabelsysteme GmbH