Hardwire
Compliance.
Stop pencil-whipping IPC-A-620 forms. AiCabler translates QA requirements into deterministic code and undeniable audit trails.
The Legacy Trap
Manual harness inspection is a bottleneck that scales linearly with production, until it breaks your margins.
Machine Vision
Meets IPC-A-620
We don't replace your QA team. We give them a deterministic engine. AiCabler analyzes cross-sectional crimp images and immediately flags Class 1, 2, or 3 violations based on strict geometric tolerances.
- Automated void measurement in crimp barrels.
- Bellmouth radius calculation to ±0.01mm.
- Insulation clearance verification.
How We Differ From Legacy Solutions
| Feature | AiCabler | OES / Schleuniger (Legacy) | Paper & Calipers |
|---|---|---|---|
| Cloud-Native API | Yes (REST & GraphQL) | On-premise isolated terminals | N/A |
| Cross-Section Image Analysis | Automated ML Pipeline | Manual visual overlay | N/A |
| Hardware Lock-in | None (Hardware Agnostic) | Proprietary microscopes required | N/A |
| Audit Trail | Immutable, Searchable JSON | PDF Reports / Local DB | Filing Cabinet |
01. The API First Engine
Connect your existing MES (Manufacturing Execution System) directly to AiCabler. Push crimp force data, pull compliance certificates, and automate the stop-line command if parameters drift.
Read the API Docs →POST /api/v1/compliance/crimp{ "batch_id": "CH-8921-A", "wire_awg": 22, "terminal_pn": "TE-640903-1", "measurements": { "crimp_height": 1.12, "crimp_width": 2.05, "pull_force_n": 85.4 } }HTTP 200 OK{ "status": "PASS", "ipc_class_achieved": 3, "certificate_url": "..." }
Need a specific calculation?
We provide free, purely functional engineering tools for wire harness designers.
Built for
High-Reliability
Sectors
Aerospace (AS9100)
Traceability down to the individual operator and tooling serial number. Strict Class 3 compliance enforcement.
Medical Devices (ISO 13485)
Validation protocols and 21 CFR Part 11 compliant audit logs for electronic records.
EV Automotive
High-voltage cable validation. Manage the transition from USCAR to specific OEM stringent requirements.
Defense
ITAR-compliant isolated instances available. Support for MIL-DTL-22520 crimp verification.
"Most harness manufacturers aren't failing because they lack skill; they are failing because their QA data lives in spreadsheets and 3-ring binders, making it impossible to detect tooling wear before it produces scrap."
Common Questions
Does AiCabler integrate with Schleuniger or Komax machines?
Yes. We ingest Crimp Force Monitor (CFM) data via API or CSV drop. However, AiCabler focuses on the *validation* side (cross-sections, pull tests) rather than replacing the onboard CFM.
How do you handle visual inspection requirements?
Operators upload photos via our tablet interface. Our computer vision models flag missing tie-wraps, incorrect pinouts, and insulation damage. The human operator reviews and signs off.
Is it cloud-only?
Our standard offering is SaaS. For defense contractors requiring ITAR compliance, we offer a virtual appliance for on-premise deployment.
Read Our Technical Guides
Mastering IPC-A-620 Requirements
A deep dive into Class 1, 2, and 3 differences, common defects, and how to set up an automated audit trail.
Crimp Cross-Section Analysis
How to properly cut, polish, and measure crimp profiles to detect voids and asymmetric deformation.
Pull Force Testing Standards
Understanding UL 486A-486B and MIL-T-7928 requirements for tensile strength in wire terminations.
Drop-in Integration
Work Orders
Compliance Cert
Stop Guessing. Start Verifying.
Join the manufacturers who have eliminated paperwork and guaranteed IPC-A-620 compliance on every harness shipped.
View Pricing Plans