ÖLFLEX® CONNECT
WHERE QUALITY
MEETS CONNECTIVITY
WHERE QUALITY
MEETS CONNECTIVITY
Powering the World
from the Inside
from the Inside
With more than 60 years of experience in delivering flexible and
durable custom-cable solutions, LAPP offers expert connectivity
services for your specific business needs. Bringing together 8
dynamic brands from LAPP, ÖLFLEX® CONNECT allows
you to have complete connection solutions from a single source.
Ready to support diverse industries, discover how ÖLFLEX®
CONNECT brings together the perfect combination of products,
services and industrial know-how to handle your connectivity
needs for maximum productivity.
Getting the Best Crimp for Your Wiring Harness
While crimping wires appears simple, lower tier manufacturers
often lack the necessary equipment and expertise for flawless
results. Whether using hand tools or fully-automated machines,
engineers ought to oversee the process to ensure strict adherence
to specifications. At LAPP, we meticulously address all aspects of
wire harness crimping to deliver tailored solutions for our
clients' unique needs.
1
Full encasing of wire's insulation within crimp tab
Crimping relies on the tab to securely fasten the wire and
fully encase its insulation. With stripped wires, adequate
wire length is essential for complete encapsulation. This
tab not only provides a firm clutch but also reinforces the
connection by gripping the insulation. For unstripped wires,
we employ crimp tabs capable of direct contact with the
wire, creating efficiency and wire integrity. This process
ensures each product performs as intended, from assembly
line to client delivery.
3
Checking connectors to ensure secure wire retention
Preventing loose connections is paramount for optimal power,
data, or signal transmission. Throughout the wire terminal
connection process, multiple checks are conducted to ensure
robust retention.
5
Identifying tears, pulls, or other defects in the
insulation
To provide utmost quality, we keep a constant lookout for
any insulation imperfections using a micrograph, enabling us
to analyse cross-sections of crimped terminals at a
microscopic level. Through polishing and/or electrolyte
staining, our quality assurance team can spot even the
smallest of defects in the insulation and other integral
components, mitigating any risk of premature failure. This
commitment instills confidence in our clients, especially
those in critical sectors like medical, military, industrial
control, and telecommunications, where our products are
indispensable.
7
Final product inspection
Strictly adhering to stringent quality standards as a custom
wire harness manufacturer, we scrutinise every aspect to
avoid any potential instance of wire separation, wire
damage, insulation damage, or abnormalities within
terminals, connectors, wires, or other components.
2
Verifying wire integrity prior to crimping
Before exploring crimping options, it's imperative to
evaluate the wire’s quality. At LAPP, we rely on
UL-certified wires with precise specifications, empowering
our engineers to accurately predict the final product's
performance in diverse conditions. Starting with a proven,
high-quality product establishes the groundwork for a
reliable wiring harness. Even with superior crimping
techniques, the end product's excellence will be compromised
with faulty wires.
4
Examining crimp indentations
In modern electronics, wiring harnesses serve as the
backbone of wire management infrastructure. Crimp
indentations are essential for both wire management planning
and presentation. Proper alignment is important in ensuring
the crimping tab establishes solid contact and securely
grips the wire. With various crimping profiles available,
achieving the appropriate indentation at precise angles is
essential for maintaining the integrity of the connection.
6
Preventing wire insulation damage by crimp tabs
While incorporating insulation within crimp tabs enhances
connection integrity, engineers must remain vigilant to
avoid wire insulation damage. Delicate wiring harness
components are susceptible to inadvertent damage,
necessitating continuous checks throughout the manufacturing
process.
Applying an exact exertion of force when using crimping tools, especially hand-tools, is essential in gripping the wire without causing insulation damage. This principle of careful handling applies across all manufacturing phases, to prevent premature harness damage or degradation due to insulation defects.
Applying an exact exertion of force when using crimping tools, especially hand-tools, is essential in gripping the wire without causing insulation damage. This principle of careful handling applies across all manufacturing phases, to prevent premature harness damage or degradation due to insulation defects.
1
Full encasing of wire's insulation within crimp tab
Crimping relies on the tab to securely fasten the wire and
fully encase its insulation. With stripped wires, adequate
wire length is essential for complete encapsulation. This
tab not only provides a firm clutch but also reinforces the
connection by gripping the insulation. For unstripped wires,
we employ crimp tabs capable of direct contact with the
wire, creating efficiency and wire integrity. This process
ensures each product performs as intended, from assembly
line to client delivery.
2
Verifying wire integrity prior to crimping
Before exploring crimping options, it's imperative to
evaluate the wire’s quality. At LAPP, we rely on
UL-certified wires with precise specifications, empowering
our engineers to accurately predict the final product's
performance in diverse conditions. Starting with a proven,
high-quality product establishes the groundwork for a
reliable wiring harness. Even with superior crimping
techniques, the end product's excellence will be compromised
with faulty wires.
3
Checking connectors to ensure secure wire retention
Preventing loose connections is paramount for optimal power,
data, or signal transmission. Throughout the wire terminal
connection process, multiple checks are conducted to ensure
robust retention.
4
Examining crimp indentations
In modern electronics, wiring harnesses serve as the
backbone of wire management infrastructure. Crimp
indentations are essential for both wire management planning
and presentation. Proper alignment is important in ensuring
the crimping tab establishes solid contact and securely
grips the wire. With various crimping profiles available,
achieving the appropriate indentation at precise angles is
essential for maintaining the integrity of the connection.
5
Identifying tears, pulls, or other defects in the
insulation
To provide utmost quality, we keep a constant lookout for
any insulation imperfections using a micrograph, enabling us
to analyse cross-sections of crimped terminals at a
microscopic level. Through polishing and/or electrolyte
staining, our quality assurance team can spot even the
smallest of defects in the insulation and other integral
components, mitigating any risk of premature failure. This
commitment instills confidence in our clients, especially
those in critical sectors like medical, military, industrial
control, and telecommunications, where our products are
indispensable.
6
Preventing wire insulation damage by crimp tabs
While incorporating insulation within crimp tabs enhances
connection integrity, engineers must remain vigilant to
avoid wire insulation damage. Delicate wiring harness
components are susceptible to inadvertent damage,
necessitating continuous checks throughout the manufacturing
process.
Applying an exact exertion of force when using crimping tools, especially hand-tools, is essential in gripping the wire without causing insulation damage. This principle of careful handling applies across all manufacturing phases, to prevent premature harness damage or degradation due to insulation defects.
Applying an exact exertion of force when using crimping tools, especially hand-tools, is essential in gripping the wire without causing insulation damage. This principle of careful handling applies across all manufacturing phases, to prevent premature harness damage or degradation due to insulation defects.
7
Final product inspection
Strictly adhering to stringent quality standards as a custom
wire harness manufacturer, we scrutinise every aspect to
avoid any potential instance of wire separation, wire
damage, insulation damage, or abnormalities within
terminals, connectors, wires, or other components.
TRANSFORMING CUSTOMER CHALLENGES INTO ADVANTAGES
LAPP's customer-centric approach transforms operations with
ÖLFLEX® CONNECT, addressing unique challenges like
optimizing Thai Cold Rolled Steel Sheet (TCRSS)’s existing
40-tonne Electrical Overhead Travel Crane (EOTC) system.
We were impressed by LAPP team’s commitment to complete the
installation; they were able to troubleshoot for us on-site
promptly, and even returned 2 months later, to ensure the
chain system was running well; and that every part (was)
perfectly in place.
- Thai Cold Rolled Steel Sheet
Substantial
savings
savings
Robust cable protection minimised maintenance downtime,
unlocking cost savings.
Safer &
more efficient
more efficient
Maximising productivity while addressing safety concerns
boosted overall efficiency.
Smarter use
of space
of space
No more cabling headache - the streamlined and tidy cabling
system created extra space on the factory floor.
Quality Assurance for Peace of Mind:
LAPP’s Dedication to Rigorous Testing & Custom Solutions
LAPP’s Dedication to Rigorous Testing & Custom Solutions
Our team dedicates a substantial amount of time for quality control
throughout production as we believe it is crucial for success in
everything we do at LAPP. Serving a wide array of applications and
industries, all our products undergo rigorous testing to ensure
integrity, safety, and functionality, providing clients a peace of
mind. Priding ourselves on being custom wire harness manufacturers,
we design over 50% of our assemblies and harnesses, building an
extensive knowledge base.
With over 2,000 existing tools, connections and components, LAPP’s design team is capable in delivering prompt and cost-effective solutions. Embedding technology in each connectivity component, quality is inherent from the start.
With over 2,000 existing tools, connections and components, LAPP’s design team is capable in delivering prompt and cost-effective solutions. Embedding technology in each connectivity component, quality is inherent from the start.
Ready to explore working with a custom harness
manufacturer?
Connect with our team of ÖLFLEX® CONNECT, cable and wire harness professionals at
Connect with our team of ÖLFLEX® CONNECT, cable and wire harness professionals at