Precision Cable Assembly

Blue Clover Devices does not believe in following the pack. With “Dare to Innovate” as a core value, we believe in the discovery of innovative ways to eliminate waste. We apply this philosophy to everything we do, including the construction of precision cables.

When new connectors were built to reduce space in smart phones and improve reliability, we rose to the challenge and added cable manufacturing to our portfolio in support of our clients. But we did not look like other cable factories. We saw plenty of capacity out there for pulling the raw conductive wire, and we decided to focus on the tricky parts of the assembly: the dozen or so invisible steps to terminate the cables with ever-more complex connectors. Today’s cables are actually devices, with ICs that communicate with the other devices they are plugged into. This is the only way to reach the data and power transfer requirements demanded by modern infrastructure. Precision cables adhering to USB Type-C, lightning, and automotive standards are a growing business segment at THE IoT ODM.

In our exploration of how to best produce cables, we test a lot of manufacturing equipment. We often find that the more expensive equipment was more precise, easier to maintain, and more durable. We run the same products through multiple production lines with subtle differences so we can experiment and optimize for quality, speed, and cost. We choose equipment that fits within the footprint of our standard “A1” tables which are 1m x 0.7m in surface area.

“Quick, clean, and quiet” is our mantra for manufacturing. Our ultrasonic welding equipment is from Switzerland and is extremely quiet, unlike other machines we considered. We don’t believe that manufacturing must be noisy, confusing, and dirty. In our quest to modernize cable assembly we have acquired the knowhow, the equipment, and the systems to make superb cables in a cost-effective way.
We use robots and lasers to perform steps that would be problematic for people to do on their own. We treat our equipment as high-performance tools to help our team produce more efficiently rather than pushing automation for its own sake.
Some of the common processing steps we have mastered in cable making include:

  • Wire Cutting
  • Jet Dispensing
  • UV Glue Preparation
  • Ultrasonic Welding
  • Injection Molding

We test every single cable we make and have not received a single defect from the field.  This speaks to our “Quality First” mindset which is just another way we eliminate waste. We know that cables provide a critical link in the systems where they are used and we treat them with great care.  When you are looking for a dependable manufacturer of precision cables, look to Blue Clover Devices, THE IoT ODM.

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