Custom Wire Harness Manufacturing | Box Build Manufacturing in Pa.


Since 1986, CAI has delivered custom-built, high-quality component and wire harness manufacturing to customers across the globe. Offering a personalized approach to every project, CAI partners with customers to create innovative products that exceed industry standards. Whether they’re creating niche product prototypes or helping a customer turn their idea into a full production run, CAI’s turnkey manufacturing approach delivers a complete product from design to delivery.

In-House Manufacturing Services

Wire Harness Assembly

From high-mix, low-volume requests to high-volume and beyond, CAI is a custom wire harness manufacturer offering capabilities both domestically and offshore to support our customers’ individual needs. We recognize that every customer is different, and confidently provide all harness and cabling applications, from simple point-to-point contacts to complex harnessing and overmolding. CAI is your one-stop shop for high-capacity wire harnesses and custom turnkey manufacturing services.


Overmolding Cable Assembly

CAI is a custom cable assembly manufacturer of custom overmolded cable assemblies for superior durability, secure connectivity, and branded solutions. We work with heavy-duty materials that can assist with keeping your harnesses organized and we can design and build rugged overmolded wire harnesses. As a customer-centric wire harness manufacturer, we take pride in creating assemblies that match our customers’ specific needs, which can change based on the area in which their cable assembly is being used and the environmental factors it is likely to encounter. The cables created at CAI can be customized to protect your harnesses from heat, friction, moisture, abrasion, compression, and more.

Electronic Assemblies &
Custom Box Build

Through CAI and our partner companies, we provide high levels of process integration, including PCBA (printed circuit board assembly), metal fabrication, plastic molding, printing and finishing for subassembly, plug and play, and turnkey solutions. Our company is a manufacturer of custom automotive electronics assemblies, and customized box and panel builds for companies in industrial spaces, the specialty automotive industry, and beyond.

Electro-Mechanical Assemblies

With a history of providing superior electrical services, engineering staff, and diverse fabrication capabilities, CAI is a proven source for electro-mechanical and mechanical assemblies. These assemblies can be utilized in a wide array of industry-specific products, from joysticks and sensor builds to junction boxes, food service equipment, and more. We are a custom wire harness manufacturer with turnkey capabilities from overmolding to assembly.

Our Processes

In order to consistently deliver the superior products and services we do on a regular basis, CAI offers extensive process integration capabilities, largely comprised of those listed below. As a company, we continue to do whatever it takes to make sure our customers receive the perfect product at the end of their journey with us. From prototype to production, CAI will work with you to make sure your vision is fully realized and exceeds your expectations. Take a moment to review our comprehensive list of process integration capabilities and contact us about your project today.

Industries We Serve










Choosing the best connectors and terminals

Choosing the Best Connectors and Terminals for Your Custom Wire Harness

What to Know When Choosing the Best Connectors and Terminals for Your Wire Harness Needs Choosing the best connectors and terminals for your application is important when customizing an electrical wire harness for your application to assure consistent and proper connectivity, data and power transmission. Connectors (most often specified as UL Listed) connect similar electrical conductors (e.g....
Custom Overmolded Cable

Custom Overmolded Cable and How It Can Improve Your Assembly

 Custom Overmolded Cable Assembly Benefits & Options Designed to provide optimal protection of your electrical circuitry, an electrical cable assembly is a set of electrical wires or cables wrapped in a single insulating sleeve often made of thermoplastic, vinyl, or thermoplastic rubber. Unlike wire harnesses, which are typically housed internally, cable assemblies must deal with external...
Plastic resin CAI

Choosing the Right Plastic Resin for Your Custom Injection-Molded or Overmolded Component

For Your Custom Plastic Resin Part to Perform Its Best, Start with These 5 Key Questions The plastic in TVs, cars, medical devices — They’re not all the same, though you wouldn’t be alone in thinking so. In fact, there’s a multitude of plastic part types, made from many different types of resin, each with their own unique traits, strengths, and weaknesses. While ABS, polypropylene, nylon,...
Potting Protects Custom Electronic Components

How Potting Protects Your Custom Electronic Components

Peak Protection Starts with Choosing the Right Potting Compound Material. If you need your custom electronic components to perform their best while enduring threats like moisture and heat, then you might want to consider the many benefits of potting and how to choose just the right potting compound.

cosmetic options for wire harness

Do You Need Cosmetic Options For Wire Harness Assemblies?

Because CAI is committed to surpassing our customer’s expectations, we don’t just offer harness assemblies. We provide customized cosmetic options for wire harness assemblies that will serve to increase their safety and functionality. Taking Functionality to a New Level Most of our products may be hidden in the core of precise manufacturing projects, however, our cosmetic options become...

CAI Offers Access to the Latest Technology of 3D Scanners Saving You Money

If you're looking for a way to make your preproduction process easier while stepping up your competitive edge, CAI is the perfect partner for your business. We offer our customers competitive benefits such as 3D printing that allow for rapid prototyping. When it comes to the manufacturing process, access to cost-saving solutions and knowledgeable professionals creates a huge advantage. Our...


Not only is CAI capable of manufacturing wire harnesses, but they can provide specialty injection molding and overmolding processes to ensure your wires and wire harness assemblies are robust, well secured, and protected by various forms. WHAT IS INJECTION MOLDING Simply stated, injection molding is the process of injecting melted plastic resins into a mold. Once the plastic sets-up, becoming...
wire harness medical industry trends

Wire Harness Medical Industry Trends

CAI has been operating and supplying custom parts that support wire harness medical industry trends for years. The demand for telehealth services and robotics automation has grown, resulting in a greater need for custom wire harnesses and assembly solutions that meet the new demand. CAI is the silent contributor to the success of these trends, providing your solution to manufacturing...
safer work environments


Create a safer work environment with CAI’s precise wiring and harnesses. We can help you control your equipment and a reduce liability exposure. Safety Matters. We prioritize safety by creating components that work with your systems and protect your workers.  Our company can help take your industrial site’s safety to the next level. We produce wiring and harnesses that support safety functions of heavy equipment. Products include the power and signaling for safety mats and beams used around heavy equipment. If a worker is sensed or makes physical contact with the operating area of a machine, it can be forced to retract or shut down.

Robotics Industry


CAI has been manufacturing specialty products that surpass their customer’s expectations for decades. When it comes to the robotics industry — mechanically powering functions with or without a necessary hands-on human interface — we have the ability to support a variety of applications with electrical and technical interfacing. We have the proven ability to manufacture specific robotics pieces...


CAI’s domestic and offshore capabilities are a perfect blend for my client’s unique and dynamic custom cable requirements. They handle fast turn or blanket orders. They’re excellent communicators, provide great service, aggressive pricing, and aggressive lead times.  They check all the boxes!

Owner, G2 INC.

CAI’s development support and production turnaround of the ruggedized over molded harness assembly, enabled the on time and successful launch of our recent supply system.  Thank you all!!


Cranberry Twp. PA


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