Case Study: High-Flex Robotic
Wire Harness Assembly

How Cablum, a leading industrial wire harness manufacturer, engineered a custom overmolded drag chain solution that eliminated field failures and extended lifespan by over 300%.

Step 01

The Customer's Challenge

An industrial robotics manufacturer was experiencing costly, premature failures in their multi-axis robot arms due to cable fatigue. The constant, repetitive motion was causing standard cables to break down, leading to machine downtime and customer dissatisfaction.

They needed a complex, multi-branch harness with an exceptionally high-flex life designed specifically for dynamic drag chain applications to eliminate these field failures.

Step 02

The Cablum Solution

Through a detailed Design for Manufacturability (DFM) analysis of the robot arm's movement, we identified the key stress points. Our solution focused on material science and structural design:

Material Selection (PUR/TPE)

We proposed using a specialized high-flex life TPE jacketed cable with finely stranded copper conductors, rated for over 10 million flex cycles and resistant to industrial cutting fluids.

Custom Overmolding

We designed a custom overmolded strain relief for their M12 and M8 interconnects. This distributed bending stress over a wider area, preventing sharp kinks at the connector interface and ensuring IP67 sealing.

Step 03

The Implementation Process

Our team created 3D models of the overmold for client approval and produced rapid prototypes. These samples were then subjected to millions of cycles on our in-house swing/flex life tester to validate the design. The results confirmed our engineering calculations, and we moved to mass production with a fully documented and controlled process.

Step 04

The Results

The new assembly was a resounding success, delivering transformative results for the client:

Product Lifespan Increased by 300%: The new high-flex harness extended the robot arm's operational lifespan far beyond the original design goal.
Field Failures Eliminated: Warranty claims and costly service calls related to cable fatigue dropped to nearly zero.
Enhanced Brand Reputation: The client's product gained a reputation for extreme reliability and durability in the automation market.

Case Study Q&A

We manufacture a wide range of custom industrial interconnects, including high-flex robotic cables, drag chain harnesses, sensor cables (M8/M12/M23), and heavy-duty power assemblies for manufacturing equipment and CNC machines.

Yes. We engineer high-flex cable assemblies using specialized PUR/TPE jackets, finely stranded copper conductors, and optimized twist pitches. Our solutions are designed to survive millions of flex cycles in dynamic drag chain and multi-axis robotic applications.

Absolutely. We provide in-house custom overmolding for industrial connectors to ensure IP67/IP68 ingress protection against water, cutting fluids, and dust, while delivering superior strain relief in harsh factory environments.

Custom industrial robotics wire harness and high-flex drag chain cable assembly

Project Snapshot

Client: Robotics OEM
Industry: Automation
Challenge: Cable Fatigue
Solution: Overmolded High-Flex

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Case Study: High-Flex Robotic Wire Harness Assembly