Production: Shanghai
Warehouse & Sales: Frankfurt
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Confidentiality notice: The case examples shown here are based on real project constellations from our core business areas. For reasons of contractual confidentiality (NDA), customer names, locations and identifying details are not published. All metrics and requirements mentioned are exemplary and abstracted to industry-typical patterns. The Robotics entry describes our capability profile — without a fictitious project.
Case Studies

Nine industries. Six projects. One frontier.

From ambulance modernization to surgical robot control cables — the case examples below show how we translate specific customer requirements into manufacturable cable harness solutions. For reasons of contractual confidentiality, customer names are not disclosed.

6 + 1Branchen + Zukunftsfeld
ab 1units, batch size
100 %final inspection
48 hErstangebot
Mainstar Kabelbaum mit Detail-Callouts - Wireframe-Illustration
Case 01
Special Vehicles
2024
Sonderwagen — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Southern Germany · Special vehicle constructionSouthern Germany · Special Vehicles

Complete harness for ambulance generation 2025

Challenge

A new generation of ambulance required 40% more sensors (patient monitoring, telemetry, GPS routing). The existing harness supplier could not meet the combined requirements of IP67, EMC integrity and a unit cost ceiling. The body manufacturer was about to delay the series launch.

Our Solution

New development as a 142-conductor hybrid harness with EMC-shielded data bundle, IP69K connectors and integrated LIN/CAN diagnostic interface. Safety-critical connections (warning signals, vehicle power) via laser soldering. CAD-designed routing minimizes kink points; pre-assembled modules speed up final assembly at the body builder.

8 → 4 weeksdelivery time halved
−22 %unit cost vs. predecessorUnit cost vs. predecessor
0complaints in 18 months / 240 vehicles
DIN EN 1789compliance confirmedCompliance confirmed

"For the first time, we have a harness partner who keeps our production rhythm and accepts the special body-builder requests at the same time."

— Technischer Leiter Aufbau (Kunde · Sonderfahrzeugbau, NDA)
Case 02
Agricultural
2023
Agrarwagen — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Northern Germany · Agricultural OEM

Sensor harnesses for self-driving harvester

Challenge

A field return rate of 8% strained the warranty budget. Root cause: jacket abrasion from vibration, dust ingress at connectors, crushed strands at sharp-edged routing. During harvest, every standstill means five-figure yield losses per machine.

Our Solution

Hybrid cable with scratch-resistant corrugated tube jacket, IP6K9K connectors with secondary locking, vibration-decoupled clamp points with silicone dampers. On-site routing analysis with the customer engineering team — seven kink points eliminated by design.

8 % → 0,9 %Field-Return-Quote
12.000 hachieved in field testing
3 yearswarranty without complaintwarranty without complaintwarranty without complaint case
35.000 St./J.series launch
Case 03
Automotive
2024
Automobil — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Southern Germany · Automotive Tier 1

DC charging harness for 800V EV platform

Challenge

A Tier-1 supplier needed a CCS2 charging harness for a new 800V electric platform with high-current paths up to 350A — fully PPAP-documented, IATF 16949-compliant, ramping to 250,000 units/year in 11 months. The previous European supplier was 38% over target cost.

Our Solution

Series concept with automated crimping under SPC monitoring, 100% final inspection including hipot and isolation test (2.5 kV). In-house tool engineering in Shanghai for unit cost optimization; production launch with German on-site process audit.

Cpk = 1,82(requirement ≥ 1.67)
0 ppmcomplaints at series launch
−38 %unit cost vs. previous supplierUnit cost vs. prior supplier
PPAP Lvl 3approved in 14 weeks
Case 04
Industrial
2023
Industrie — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Western Germany · Robotics OEM

Cable chain harness for 6-axis welding robot

Challenge

In high-frequency automotive welding cells, control lines failed after about 4M flex cycles — well before expected lifetime. Downtime cost: around €18,000 per event due to line rhythm loss and robot re-teach.

Our Solution

Hybrid cable chain harness with PUR jacket, EMC-shielded data conductors and precisely stranded wires for a defined bend radius. Cable lengths assembled individually per robot type; every batch delivered with a flex cycle certificate.

> 7,5 Mio.flex cycles in lifetime test
3 → 9+ yearsservice life tripled
320 Anlagenequipped, no field failures
48 hoursWarehouse Frankfurtdelivery time from Frankfurt warehouse

"Since the switch, we have downgraded the cable chain in our maintenance schedule by two tiers."

— Head of Maintenance (Customer · Robotics OEM, NDA)
Case 05
Energy
2024
Energie — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Southern Germany · Energy projectsSouthern Germany · Energy Projects

String cable assembly for 25-MWp PV park

Challenge

47,000 modules, 1,500V DC per EN 50618, 25-year service-life guarantee. Construction window of only three months, very tight just-in-sequence delivery. Prior projects had suffered from on-site assembly — connector mounting errors caused yield losses in the first year of operation.

Our Solution

Pre-assembled string cables on pre-cut reels, IP68 connectors factory-mounted and 100%-tested, individual marking per string number. Delivery in seven tranches across nine weeks exactly to construction schedule — no intermediate site storage.Pre-assembled string cables on pre-cut reels, IP68 connectors factory-mounted and 100%-tested, individual marking per string number. Delivery in seven tranches across nine weeks exactly to construction schedule — no intermediate site storage.

+30 %installation speed
0on-site connector assembly errors
25 yearswarranty per IEC 62930
9 weeksdelivery period
Case 06
Medical
2024
Medizin — Wireframe-Illustration
Kunde · NDA
Customer under confidentiality
Ostdeutschland · Medizintechnik

Control cable for 4K video endoscope platform

Challenge

Highly miniaturized control cable in AWG-30 multi-coaxial design for a new 4K video endoscope. Requirement: 1,000 autoclave sterilization cycles, ISO 13485, full traceability from strand batch to delivered device. Classic reflow soldering caused too much thermal stress on adjacent micro-components.

Our Solution

Laser soldering instead of reflow — precise energy input without thermal load on adjacent components. Clean-room assembly, QR-code tracking from every batch back to the strand batch. Validation samples within six weeks, series release per FDA 510(k).

0device failures after 4,500 units
FDA 510(k)approved without complaint
100 %Traceability: series → batch → lot
1,200 cyclessterilization resistance of control cable

"Laser soldering solved a problem we could not get under control with classic reflow."

— Head of Endoscopy Development (Customer · Medical Technology, NDA)
Capability
Robotics · Frontier
2026
Humanoide Robotik / Interconnect-Systeme — Wireframe-Illustration
Open for pilot partners
Humanoid robotics · OEMs & Research
Service robotics · Industrial humanoids · Cobotics

Ready for humanoid robotics pilots

Marktanforderung

Humanoid robotics demands from cable harnesses what classic industrial robotics never required: millions of flex cycles per joint at minimal installation space, EMC-critical sensor lines directly next to high-power servo drives, FPC hybrids for data rates in the Gbit range, integrated connectors for tool-free maintenance. Standard cable-chain harnesses fail here on bend geometry, weight and cross-section.

Unser Capability-Profil

We bring manufacturing discipline from automotive (IATF 16949) and medical (ISO 13485), plus high-flex experience from industrial cable chains, into the robotics field. Joint cable modules with high-flex strands, FPC cable hybrids, EMC shielding and connector assembly per IPC/WHMA-A-620 Class 3 — all from our own production, from batch size 1. First samples typically within six weeks.

10 Mio.+Biegezyklen, ausgelegte Module
IPC/WHMA-A-620Class 3 — High-Reliability
FPC-HybridFlat conductor + strand in one harness
from batch size 1Prototype to small batch

"Rather than fabricate a case, we make visible what we bring: manufacturing discipline from automotive, high-flex know-how from industrial robotics, and the willingness to develop together with pilot partners."

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