Gaffney Test - CAI


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










Solid vs. Stranded: Which Wire is Best for Your Electrical Application?

The Pros & Cons of the Two Types of Electrical Wires One of the key decisions to be made when manufacturing an electrical system, such as a wire harness or cable assembly, is whether to use solid wires or stranded wires.  Every electrical wire includes conductive material, typically copper, that is responsible for carrying electricity — and the power and data in it — from one place to...

Wire & Cable Conductors: Purpose, Materials, & Coatings

Understanding Common Conductor Types for Wires & Cables   At the center of each electrical wire, and each individual wire within a cable, is a conductor which is the electrical highway for carrying power or data from one point to another. Conductors are typically made of metals due to their ability to effectively conduct electricity. However, different metals feature different...

Wire Harness Labeling: What It is & Why It Matters

Effective Wire Harness Labeling Enhances Maintenance, Safety, & Compliance   Wire harnesses facilitate the flow of power and data for a vast majority of complex electrical systems we rely on every day, from automobiles to airplanes. Within a wire harness, there are a number of different components, wires, and connection points that typically require accurate systematic labeling, or...

Wire Harness vs. Cable Assembly: Which is Best for Your Project?

Understanding the Difference Between Wire Harnesses & Cable Assemblies   Without the wires and cables that transmit power and data to and from many of our electrical devices, our world would be a much different place, one seemingly stuck in the 1800s. No TV or radios. No Internet or phones. No cars or planes. No machines to mass-produce the many products we get at our local department...

8 Key Benefits of Custom Wire Harness Manufacturing

Exploring the Main Advantages of Tailor-Made Manufacturing for Wire Harnesses Critical to the performance of many electrical devices, machines, and equipment, a wire harness is a uniformly-arranged collection of multiple wires, cables, connectors, and terminals that facilitates the efficient flow of data and power between various components of an electrical system.  For instance, a wire harness...

Legacy Devices & Overcoming the Challenges of End-of-Life Components

Handling the Progressively Shorter Lifespans of Electrical Components As technology advances faster and faster these days, businesses can have an increasingly harder time keeping up. While advancements typically enhance efficiency, they can also adversely affect bottom lines when costly machines and equipment quickly grow obsolete.  A legacy device refers to an outdated computer or other...

Reasons to Partner With CAI for Your Custom OEM Cable Assembly or Wire Harness Needs

What a Quality Original Equipment Manufacturer Like CAI Can Bring to Your Brand’s Custom Electrical Projects An original equipment manufacturer, or OEM, is a company that manufactures a product to be sold by another company. These OEM products are typically created to be an integral part of a larger system and crucial to its performance. For instance, OEM cable assemblies and wire harnesses are...

Common Types of Cable Assemblies

From D-Subs to Coaxial Cables, These Are Some of the Most Popular Types of Cable Assemblies Cable assemblies are vital to the operation of essential electronic systems in a countless number of industries from medical and telecommunications to automotive and aerospace. Without them, there would be no transmission of power and data, making such machines and devices useless.    Consisting of...

Building a Custom Cable Assembly: 6 Top Design Considerations

Keep These Key Things in Mind During the Cable Assembly Design Process   An essential part of any electrical system, utilized in a multitude of industries for transmitting power and data, a cable assembly is a collection of cables or wires organized and wrapped together in a single protective sheath to offer enhanced protection, performance, and organization. From conductors and connectors...

How You Can Save by Partnering With a Quality Turnkey Manufacturer

With over 35 Years of Manufacturing Excellence, CAI is Your Savings Solution Before undertaking or upscaling product manufacturing, it’s smart to know just what you’re up against and what it’s going to take to bring your vision to life. You may be considering using your internal overhead or creating additional internal infrastructure to “do it yourself,” but before you go down that path, you...

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.