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










Bridging the Distance: How Telecom Cables Connect the World

Understanding the 3 Most Common Types of Telecommunications Cables: Coaxial, Twisted Pair, & Fiber Optic Telecommunications, or “telecom,” refers to communication over long distances, especially via electricity. Once exclusively relegated to voice transmissions, advancements over the last century have allowed for data and video to be sent and received as well. Today, a great deal of our day...

Exploring the Different Types & Attributes of Medical Cable Assemblies

Essential to the Medical Field, Cable Assemblies Supply the Critical Power & Data Used in Medical Devices The medical field is a constantly evolving, rapidly advancing industry which relies heavily on electronic devices to create the conditions for optimal health care. While doctors, nurses, and other medical professionals play a vital role in improving the quality of our lives, so does the...

When Failure is Not an Option: Custom Military Wire Harnesses & Cable Assemblies

Mil-Specs, Applications, & Other Factors OEMs Consider When Manufacturing Harnesses & Cables for Military Use Not totally unlike those used in other industries such as construction or automotive, military electrical systems are typically designed for mobility, but must meet more highly adaptable specifications in order to perform in many diverse and extreme conditions and situations. ...

Key Considerations When Designing Custom Automotive Wire Harnesses

Vehicles Feature Complex Wiring Systems With Specific Attributes to Keep Things Running Smoothly Whether we’re heading to work, a friend’s house, or the store, it’s easy for us to take for granted that every time we get into our cars and trucks, we’re getting behind the wheel of a highly complex high-performance machine, trusting it not only to get us to our destination, but to do it as safely...

Filler Material for Custom Cable Assemblies & Why It’s Needed

10 Most Common Types of Cable Filler Material   When constructing a custom cable assembly, manufacturers often add filler material to separate different sections and/or to fill in the gaps between the conductors, or wires. Fillers serve multiple functions within a cable from providing added protection against the elements to lengthening the cable’s lifespan. While cable filler helps take up...

American Wire Gauge (AWG) System: A Valuable Resource for Choosing the Best Wires for Electrical Projects

How an AWG Chart is Used to Select the Best Wire for Each Application When designing a custom wire harness, manufacturers take many factors into consideration to help them choose the best wire to use, including its future application and overall project budget.  Because wires are available in a wide variety of widths, wire “gauges” are used as a measurement of a wire's diameter or...

What’s Watt? And Other Electrical Terminology Explained

A Brief Glossary of Key Electrical Terms The world of electronics has its own language with a seemingly limitless vocabulary. At times, terminology can be confusing or applied incorrectly, even among those familiar with it. Here we’ll provide definitions for some of the most commonly used terms when working with wires, cables and electricity. While it helps to know the language, remember that...

How Custom Cable Assemblies Are Put to the Test

Ensuring Optimal Performance, Endurance and Safety,Cable Assemblies Must Undergo a Thorough Examination Cable assemblies are the essential power and data carriers behind the machines, devices and appliances we enjoy and rely on each and every day. Before cable assemblies are shipped out and installed, they must undergo thorough testing to ensure they will effectively and consistently do their...

Wire & Cable Insulation: What Are Your Options?

Exploring the Different Types of Electrical Insulation Materials Greatly affecting the lifespan and effectiveness of wires and cables, insulation is non-conductive material used to cover and protect the conductors so they can keep the flow of data and power moving smoothly. Insulation guards against electrical leakage when the wire’s current might come into contact with other nearby wires and...

6 Main Threats to a Cable Assembly & How to Avoid Them

Enhance Your Cable’s Performance & Lifespan by Guarding Against the Common Causes of Cable Failure From the factory floor to the office building, cable failure is a leading cause of downtime which often means valuable time, resources and revenue lost. The machines and devices that power the American way of life depend on the steady flow of electrical power and data which cable assemblies and...


CAI quickly became a strong partner with their first-class service and the ability to deliver a quality product within a short amount of time. Their communication is outstanding, it should be the benchmark for any industry. It is a true pleasure working with the team at CAI.

Vastex International

Bethlehem, PA

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

Get a Custom Quote

At CAI, we consider ourselves to be a local company that provides global services. Whether you would like more information about the services we provide or our custom design and turnkey manufacturing capabilities, we would love to hear from you. Feel free to reach out to us using the form below.