DESIGN TO DELIVERY

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

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.
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Electronic Assemblies & Custom Box Build

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.
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Overmolding Cable Assembly

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.
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Electro-Mechanical Assemblies

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.
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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

Military

Industrial

Automotive

Medical

Controls

Appliances

Robotics

Telecommunication

FEATURED SERVICES

Anatomy of a Wire Harness

Understanding Wire Harnesses & Their Critical Components   Essential in everything from automobiles to diagnostic equipment, wire harnesses...

How Overmolding Makes Good Wire Harnesses Great

Overmolding Offers Wire Harnesses Greater Protection, Aesthetics, & More   Essential components in everything from robotics to medical...

7 Ways Manufacturers Ensure Fast Turnaround

CAI Uses a Combination of Strategies to Consistently Deliver Swift Lead Times   When you partner with a manufacturer to produce your complete...

9 Benefits of Hiring a Manufacturer With Global & Domestic Capabilities

CAI Thinks Global But Acts Local, Providing the Best of Both Worlds   If you’re searching for the right manufacturer to help you achieve your...

Prototyping & Its Role in Wire Harness & Cable Assembly Manufacturing

How Prototyping Ensures Optimal Results When Making Harnesses & Assemblies   In order to ensure high performance, durability, and safety in...

10 Common Types of Wire Harnesses Used in Cars

Today’s Automobiles Rely on an Intricate System of Wire Harnesses   From the engine and dashboard to the headlights and A/C, there’s an...

5 Top Questions to Ask When Searching for the Right Turnkey Manufacturer

Why CAI is the Answer for All Your Custom Electrical Component Needs   When you need to outsource the manufacturing of custom wire harnesses,...

Electrical Cable Jackets (Sheaths): Purpose, Types, & Properties

As the Protective Outer Layer, the Jacket is an Essential Part of the Electrical Cable   Similar to the coats and jackets we wear on cold...

7 Common Mistakes to Avoid When Crafting a Cable Assembly

For Best Results From Your Cable Assemblies, It Helps to Know What Not to Do   In the world of cable assembly manufacturing, precision and...

Why Proper Wire Harness Length Is Essential

To Realize Their Benefits, Wire Harnesses Must Be Be Optimally Sized    Designed to transmit signals and power smoothly within an electrical...

Cable Strain Relief: Critical Protection for Your Cables

CAI Overmolds Off-the-Shelf Solutions for Optimal Cable Strain Relief   Traversing long distances and used in a variety of demanding...

Waterproof Cables: What They Are & Why They’re Important

CAI Combines Off-the-Shelf Solutions With Overmolding to Protect Cables From Water   Electrical cables and wires are all around us, whether...

Electrical Wire & Cable Crimping: Benefits & Methods

Understanding the Go-To Joining Method for Electrical Cable & Wires   Secure, reliable connections are vital to the performance of cables,...

The Importance, Benefits, & Techniques of Proper Cable Management

Quality Cable Management is a Must for a Safe, Efficient, & Attractive Environment   With all the technology, screens, vehicles, and...

How to Get the Most Accurate Quote for Your Cable Assembly Project

Top Factors to Consider When Requesting a Cable Assembly Quote   Building a high-quality, highly reliable electrical component such as a cable...

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...

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,...

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...

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...

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...

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...

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...

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...

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...

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...

3 Top Benefits of Overmolding for Your Custom Cable Assembly

From Maximizing Lifespans to Enhancing Performance, Overmolding Brings Big Benefits to Cable Assemblies Using sophisticated injection-molding...

Why It’s Wise to Trust an Expert for Your Custom Box Build and Module Sub-Assembly Needs

Advantages of Working With a Specialist to Create Ready-to-Use Custom Box Builds and Module Sub-Assemblies   Box build assemblies, or “box...

Avoid These 8 Common Mistakes When Assembling a Custom Wire Harness

For a Job Done Right, Trust an Expert Manufacturer With Your Custom Wire Harness Needs As wiring has become much more complex over time, especially...

What Are Electromechanical Assemblies?

Understanding the Common Types of Electromechanical Assemblies The term “electromechanical assemblies” is a broad one covering everything from full...

Why Outsourcing Your Custom Manufacturing Needs May (or May Not) Be Your Best Move

Answer These 4 Questions to Decide if Outsourcing is Right for You   If you had the resources, staff, space, skill, time, and money to take...

The Importance of Wire Harnesses & Cable Assemblies in Automation & Robotic Systems

Features & Benefits of Robotic & Automation Cable Assemblies & Wire Harnesses   From the vehicle assembly floor to the surgery...

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,”...

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...

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...

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...

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...

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...

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...

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...

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...

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...

How to Pick the Right Cable Shielding for Your Cable Assembly

Braided, Foil or Spiral: Which Is Best for Your Specific Application? When manufacturing a cable assembly, it’s important to ensure that the...

Understanding the 4 Key Stages in the Custom Wire Harness Manufacturing Process

How Experienced Manufacturers Fabricate High-Quality Custom Wire Harnesses Carrying power and data to the appliances, machines and devices we use...

Heat Shrink Tubing & 4 Ways It Improves Wires & Cables

A Valuable Step in Cable Assembly & Wire Harness Manufacturing, Heat Shrinking Offers Enhanced Protection, Insulation & More When...

CAI Celebrates 35 Years of Superior Custom Manufacturing

Thanks to Everyone Who’s Played a Part in Their Success, CAI Is Poised for an Even Brighter Future Ahead On Wednesday, October 19, Corey Associates...

Cable Shielding & Why It’s So Important for Electrical Cable Assemblies

For Optimal Performance, Proper Cable Shielding Is a Must Anytime you’re working with an electrical system such as a cable assembly, you’re dealing...

4 Big Reasons to Outsource Your Custom Manufacturing Needs

Partner With a Quality Integrated Manufacturer for Best Results   Whether your business needs a custom plastic part, wire harness or overmolded...
Soldering vs Crimping

Soldering or Crimping: Which Is Better for Your Electrical Needs?

Weighing the Pros & Cons of the Two Most Popular Joining Methods For a complex electrical system to run properly, its collection of wires,...
Custom Part, Harness or Assembly Manufacturer

How to Choose the Best Custom Part, Harness or Assembly Manufacturer

Look for These Key Traits When Choosing the Right Manufacturer for Your Custom Projects Trusting others with your manufacturing needs is an...
Your PCBA Needs

Which Is Better for Your PCBA Needs? SMT or THT Mounting

Exploring Surface-Mount vs. Through-Hole Technology for Your PCBA Needs Reading this on your smartphone or PC, you are utilizing one or more of what...

Testimonials

The team at Corey Associates not only provides a quality product with quick turnaround on quotes and delivery but are great communicators and have excellent customer service. It is a pleasure working with the team over the past 5 years.

YOKOGAWA FLUID IMAGING TECHNOLOGIES, INC.

MAINE

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!!

PIMIOS

CRANBERRY TWP. PA

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.

I have worked closely with Corey Associates for the past 15 years. They have shown a perfect record in delivery and quality performance over that time. They are a helpful and cooperative supplier that we count on to meet our customer expectations.

Ken Smith

Director of Procurement

Legrand, North and Central America

CAI is a strong supply partner. They are customer and quality focused. Over the last 15 years, they have consistently provided competitive quality solutions to our requirements using both their domestic and international resources.

ENERCON TECHNOLOGIES

GRAY, MAINE

Enercon Technologies

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.