Cable assembly and cable manufacturing to customer specification – from prototype to large-scale series, Made in Germany.
WIR electronic GmbH
Chemnitz · SaydaNew on Amplifa
About WIR electronic
WIR electronic GmbH is a family-owned company based in Chemnitz specializing in cable assembly and cable manufacturing, producing cables and cable harnesses to customer specification since 1987. Its portfolio ranges from individual wires with cross-sections from 0.05 mm² to 70 mm², flat ribbon, Teflon and coaxial cables, and optical fibers, through to complex cable sets, cable harnesses, control cabinet construction, panel assembly and module assembly. This is complemented by in-house plastic injection molding for connectors such as RJ45 and M12 (a-, b-, d-, x-coded) as well as the development of special solutions. With around 300 crimping tools, approx. 4000 connectors and contacts, and about 5000 stock items from 400 suppliers, the company produces batches of 1 to 10,000 cables, including ultra-short cables from 0.1 m and overlengths up to 80 m. Assemblies for aerospace, medical technology and precision mechanics/optics are manufactured in clean conditions. Every product is 100 % tested and documented; production is carried out in accordance with ISO 9001:2015 at the Chemnitz and Sayda sites.
- Site
- Chemnitz
- Processes
- Cable assembly / cable manufacturing (individual wires 0.05mm² to 70mm²), Flat ribbon cable manufacturing, Teflon cable manufacturing, Cable sets / cable harnesses, Coaxial cable assembly (from 0.05m), Optical fiber assembly, Power cable manufacturing, Control cabinet construction
- Materials
- Copper (wire/conductor), Teflon (PTFE), Plastic (injection molding/overmolding)
- Certificates
- ISO 9001:2015, 100 % testing and documentation
- Founded
- 1987
- Industries
- Aerospace, Medical technology, Precision mechanics/optics, Automation technology, Industry
- 01
Consulting and development of special solutions
- 02
Procurement (approx. 400 suppliers, approx. 5000 stock items)
- 03
Cutting to length, stripping, inserting
- 04
Crimping, soldering, tinning
- 05
Potting and overmolding (plastic injection molding)
- 06
Wiring, assembly, control cabinet and module construction
- 07
Measuring, testing, 100% documentation
- 08
Shipping
Materials and Processes
Copper (wire/conductor)
Conductor material for individual wires, data and bus lines, coaxial and power cables.
Teflon (PTFE)
Insulation material for Teflon cables, among other things for requirements in medical technology and aerospace.
Plastic (injection molding/overmolding)
Material for injection-molded connectors (RJ45, M12) and overmolding of connection points.
Locations
Chemnitz
DEHeadquarters and production
- Lot size
- 1–10,000 cables
- Materials
- Copper, Teflon, plastic
- approx. 300 crimping tools
- Testing equipment
Sayda
DEProduction site with its own ISO-9001 certificate
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly / cable manufacturing (individual wires 0.05mm² to 70mm²)Joining | – | – | – | 1 piece – 10,000 cables | Copper, Teflon, Plastic |
| Flat ribbon cable manufacturingJoining | – | – | – | – | Copper, Plastic |
| Teflon cable manufacturingJoining | – | – | – | – | Teflon |
| Cable sets / cable harnessesJoining | – | – | – | – | Copper, Plastic |
| Coaxial cable assembly (from 0.05m)Joining | – | – | – | – | Copper |
| Optical fiber assemblyJoining | – | – | – | – | – |
| Power cable manufacturingJoining | – | – | – | – | Copper |
| Control cabinet constructionAssembly | – | – | – | – | Copper, Steel |
| Data cables / bus lines (CAN, EtherCAT, PROFIBUS, PROFINET)Joining | – | – | – | – | Copper |
| Shielded lines up to 50 wire pairsJoining | – | – | – | – | Copper |
| Panel assemblyAssembly | – | – | – | – | – |
| Module assemblyAssembly | – | – | – | – | – |
| Plastic injection molding (e.g. RJ45 straight/angled; M12 a-, b-, d-, x-coded)Plastics | – | – | – | – | Plastic |
| Overlength cable manufacturing (VGA up to 50m, KVM up to 80m, DVI up to 30m)Joining | – | 80 m | – | – | Copper |
| Ultra-short cables (patch cables from 0.1m)Joining | – | – | – | – | Copper |
| Printed circuit board assemblyAssembly | – | – | – | – | Copper |
| CrimpingJoining | – | – | – | – | Copper |
| SolderingJoining | – | – | – | – | Copper |
| Potting / overmoldingPlastics | – | – | – | – | Plastic |
| Development of special solutionsEngineering | – | – | – | – | – |
| Testing and inspection of 100% of all products / documentationInspection | – | – | – | – | – |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Crimping tools | – | ca. 300 | – | – | Chemnitz |
Additional services
Quality
Every manufactured product is thoroughly inspected, tested and 100 % documented before delivery; this guarantees reproducibility even years later. The quality management systems at both sites are certified according to ISO 9001:2015 (validity 2025–2028).
| Evidence | Chemnitz | Sayda |
|---|---|---|
| ISO 9001:2015 | ||
| 100 % testing and documentation |
History
- 1987
Founding of WIR electronic GmbH; since then specializing in cable assembly and cable manufacturing.