Epec's Blog | Electronics Manufacturing Solutions

Packaging for user interface assemblies is the last step in the manufacturing process, but not a step that should be rushed. Epec pays as much attention to packaging detail as we do to design and manufacturing of custom assemblies. Because each assembly part number is customized, each has different size, mass, and shape. However, styles of user interfaces can be grouped into several categories. Experience has shown the type of packaging that works best is based on complexity of construction, shape, size, mass and shipped unit volume. No one packaging solution works for every assembly style.

One point that anyone involved with cable assemblies understands is that "every electronic or mechanical component will eventually reach the end of its life cycle". This blog post will define cable assembly obsolescence as the point in an assembly’s life cycle when it is either no longer in a usable state, meaning it is not functioning as it was designed, or there is no longer a use for the cable assembly due to technology changes.

At Epec, our staff members are our most valuable resource and we believe in empowering employees for success. In this company, we celebrate each others success and support each others challenges. We strive to attract, hire, develop and retain passionate, talented, high performing individuals that are driven by our mission which is to provide a cost savings, technical resource and delivery advantage for our customers. We are committed to recruiting the best people that want to share our success, fit in our culture and live by our core values.

This blog post addresses custom user interface testing in terms of functional test schemes that are completed prior to shipment. Generally, the first user interface assemblies shipment are for First Article acceptance testing where customers fully examine the first units for mechanical and electrical compliance to all engineering drawing and specifications.

When we think of manufacturing in the 21st Century, we picture automated machines rapidly pumping out new products with ease. So why can't the process of complex wire harness manufacturing become fully automated as well? To answer this question, we need a deeper understanding of cable harnesses and how they are prepared.

A cable harness, also referred to as a wire harness, cable assembly, wiring assembly, or wire loom, is a grouping of wires and/or cables that are used to transmit signals as well as provide electrical power if needed. The wires and cables are joined together using a combination of straps, cable ties, cable lacing, tubing (either shrink tubing or non-shrink tubing), sleeving, electrical tape, conduit, and braided extruded string.

Cable pre-molding, sometimes associated with potting or encapsulation, is used to protect the termination points from the surrounding environment.  Pre-molding involves the application of a material around the back section of a connector where the termination points are located.

The major difference between a stranded cable and solid cable is the flexibility. Within this post we will define cable flexibility with regard to ability to withstand continuous movement. Depending on your application, cable flexibility can be a factor when choosing the proper components for your cable assembly or wire harness.

The need to protect your keypad from the ever-present threat of wear-and-tear is crucial for all applications.  If your control panel is going to be used in marine environments, medical devices, or other consumer electronics, the threat of water or liquid exposure is ever present. In wet situations, it is critical that all electronic components are completely sealed off from any outside substances that could damage the device.

Many applications would be better suited using a membrane switch (low profile, flat surface keypad assembly) along with a rigid printed circuit board (PCB), replacing screen-printed silver conductors on polyester sheets.

Printed circuit boards with gold plated switch contact pads and gold plated dome switches greatly improve the reliability of your application, offering longer operating life with lower switch resistance and contact bounce.

The smallest bend radius that can be used on a membrane switch tail will depend on the type of design. Deciding factors will depend whether or not the user interface is constructed with one tail/circuit layer or dual tail/circuit layers, and where the bend is located.