Archive for Judco Mfg

Components and Processing Solutions for Large Cable Wire Processing.

Wire comes in a multitude of sizes and configurations and is used in a vast number of electrical and electronic devices and assemblies.  In recent years, efforts to reduce overall weight of a wire harness mean smaller wire gauges and thinner wire insulation are being used.   At the same time electrical demands of some products have increased the requirement for larger cable, able to handle a higher current load.  The automotive industry is a prime example of the demands to address both ranges; smaller to bring weight down for more fuel efficiency and larger for emerging applications such as electric car batteries and hybrid fuel cells.

This article will focus on processes and components used in assemblies with large cables.

Defining Large Cable Processing.
For the purposes of this article, we will discuss processing (cut, jacket strip and wire end process assembly) on wire 6 awg and larger. Also multi-conductor cables with individual insulated wires encased in an outer insulation jacket or sheath. In general, as the wire size increases, the production volume decreases.  Production volumes typically dictate whether single or multi stage processing solutions are deployed.  We will outline single and multi stage processing solutions.

Single Processing Tools

Processing tools that perform a single function.

Wire Cut

The Wezag SH Series Hand cutter series features a ratchet action and can cut wire up to 350 mm in diameter.

The Model 31 from Carpenter Mfg is a lever style wire cutter designed to cut wire and other materials.  Featuring a guillotine blade, and adjustable wire guides, the model 31 can cut material 1″ in diameter and 4″ wide.  Wire up to 0 awg can be cut and (material dependent) up to 2/0.

Wire Strip

The Carpenter 72C is a dual blade rotary wire stripper.  The 72C processes a wide range of single and multi-conductor wire.  Quick change wire guides center the wire for nick free processing.

The Carpenter 77E wire stripper is a pneumatic heavy cable wire stripper.  The large wire grippers provide high pulling power for tightly bound insulation and large cross sections.  The 77E uses fully adjustable V blades and quick change wire guides for accurate and repeatable processing.  Form blades can also be used where V blades do not provide the desired results.

The Beri.Co.Megamax is a heavy duty programmable wire stripper capable of multi-stage precision wire stripping for cable up to 25.00 mm wire diameter. The Megamax can process large OD coaxial wire. The Megamax is one of three high capacity multi-stage wire strippers available through our partner Schaefer Megomat.

Wire Crimp

UP60Wire Process Specialties supplies crimp technology for loose and reel fed contacts.  The WDT (Wezag) UP60 shown at the left is a pneumatically activated crimping press that can crimp large terminals such as battery lugs up to 180 square mm.  Interchangeable adaptors with a wide range of die sets provide maximum flexibility.

Multi-Stage Wire Processing

Process machines that perform more than one function during a single machine cycle.


The Compu-Cut 42B is a heavy duty wire and tubing cutter with a 4″ wide blade and 1″ opening.  Flat cable and tubing as well as round wire and multi-conductor cable can be processed using the 42B.  Add additional wire separators and multiple rows of material can be processed to maximize production quantities.  The cutter head is pneumatically operated and the feed unit is electrically motor driven for accurate cut lengths.

The Compu-Cut 36A is an additional option for cutting heavy duty wire. With a special guided blade holder and a standard utility knife blade, the 36A makes precision cuts on large gauge wire as well as semi ridgid tube.

Terminals and Connectors

ETCO is a supplier of terminals and connectors.  ETCO has two manufacturing facilities in the USA for processing reel fed and loose piece heavy duty terminals.  ETCO terminals are manufactured to exacting quality requirements using state of the art fabricating equipment.

 The connector at left is a top post battery terminal.  This is one of many terminal styles for heavy cable and power cords.  ETCO can also supply custom fabricated connectors to your design.

Special Processes

The Judco FLG2 processes heat shrinkable tube around large cable, battery lugs or other connector systems.  The FLG2 is energy efficient and shrinks tube fast with low cost quartz halogen bulbs and mirrors to focus light energy around the material being processed.

These are a few solutions for processing wire and cable harnesses available from Wire Process Specialties, your authority in wire processing, connectors and terminal crimp technology.  Connect Your Way to WPS to see how we can help your company reduce cost and improve the efficiency of your wire assembly processes.

Global Technology Partners in Focus: Judco Mfg.


The third installment of our Global Technology Partners series features Judco Manufacturing. Judco has been a valued partner with WPS for over 15 years. Kevin Johnson, Sales Manager for Judco has joined us today to provide some information on Judco and how some of the products they produce can be valuable to our customers in looking for ways to improve production efficiency.

WPS: Kevin, tell us the scope of products available from Judco.

KJ:  Judco specializes in push button switches, rocker switches, slide switches, toggle switches, wiring harnesses and custom designed products that can be manufactured to your detailed specifications.

WPS: Your tenure at Judco has been long and successful, tell us how long you have been with Judco.

KJ:  I have been a part of the Judco team for over thirty years and I focus on excellent customer service.

WPS: One of the attributes of an innovative company is its ability to create products that have useful applications for a large group of companies.  Such is the case of the Focus Lite series. Kevin, can you give us an overview of the Focus Lite, how it came into being and led to the introduction of the Focus Lite for our global customer base.

KJ:  A heat gun proved to be both time consuming and a waste of energy while processing 28 inch harnesses.    Our engineering staff invented the Focus Lite, heat shrink processing machine, capable of providing a uniform shrink in considerably less time and a much safer work environment.  Judco’s bench top or hand held heat shrink processing machine can cut your labor costs and cycle time by as much as 80%.   The average Focus-Lite shrink time for polyolefin tubing is 2.2 seconds versus 20-40 seconds with a heat gun.

6 FL Machines with titles

WPS: But the innovation doesn’t stop there.  Judco has recently introduced two new products, a 3D printer and fume extractor. Can you describe these products in more detail?

KJ:  Our 2X Double 3D Printer has several unique features.  We use an open source so no specialized software needed.  Our machine is a fully assembled product.  Our competitors ship in kit form, which requires assembly.

The resolution (thickness of 2D layer) of 0.10mm provides nice rounded shapes and surfaces.  We chose PLA material, which is environmentally friendly and can be purchased anywhere.

We utilize a threaded screw which allows for better control of head up and down movement.  A steel axis control is far more reliable than our competitors’ machines that use rubber belts which wear out and slip.

The printer is controlled by a motherboard with Arduino microprocessor and many 3D Solid models are available.


The FE150 Fume Extractor, with 1900 CFM capabilities, provides a safe and healthy workplace by capturing air contaminants directly at the source and safely removing them before clean air is released into the room.  There are two filter options.  A two stage polyester high efficiency cartridge designed to handle smoke, dust and mist and a H.E.P.A filter for absolute filtration.  The system provides the versatility to solve most contaminant problems.  The high CFM fan motor is completely adjustable for sound and CFM.  The fully articulating extractor is flexible and can easily adapt to each type of assembly operation.  Multiple nozzle attachments are available for specific solder and fume conditions.


WPS: Was the design to production path similar in these two cases to the Focus Lite?

KJ:  Both products came about as the need for more efficient production methods evolved.  Judco pursued a better option and decided to offer the improvements to everyone.

WPS: WireProcess Specialties provides solutions to a rapidly growing global customer base. As a representative to Judco, our goal is to extend your expertise and customer service to our customers and provide our application specific experiences. This is to show how Judco and WPS combined can best serve our customers. Can you describe how partnerships with companies like WPS can be valuable to Judco.

KJ:  Our partnership with WPS has allowed us to reach customers in areas around the world.  Excellent products offered by knowledgeable and trained experts are the key to success.  We wouldn’t be where we are today without companies like WireProcess Specialties.

Kevin, thank you for your time today. Judco continues to be a valuable partner to WPS and we look forward to many years of service to our customers. For more information on Judco, including the Focus Lite,3D printer and fume extractor, please visit our website by clicking here. Our Connect Your Way to WPS for a one on one discussion on your applications.

Wire Processing Solutions for Communication Cables

Wire Processing Techniques span a number of assembly categories. In this posting we cover some of the processing methods used in assembling a communication cable.

We will focus on a  few cable types that represent the wider variety of communications cable assemblies and share processing methods.

Coaxial Cable

Coax cable generally has several layers including an outer jacket, woven metal shield and dielectric insulation over a center conductor.  Most applications require two or three stage stripping. This wire is normally crimped into a round coaxial connector. Stripping specifications are specified by the connector manufacturer to match the connector. The connectors are loose piece and have a pin that is crimped to the center conductor and the housing is placed over the wire and crimped on. The trend of coaxial cable is consistent with other wire, that is the range is increasing. We are seeing micro coax cables and at the other end large cable such as LMR400 for large telecomm installations such as cell towers.

Wire Cut to Length.

As this wire is typically stripped in two or three stages in an offline process (see Wire Strip), wire is separately cut to length.

Model 31 manual cutter from Carpenter Manufacturing

Model 31 manual cutter from Carpenter Manufacturing


Wire Strip

As mentioned above, this wire is normally stripped in two of three stages in a fixed strip length that is specified by the connector manufacturer. These multiple stages are processed using a programmable unit which can process multiple strips in sequence. Or separating the two or three processes onto separately adjusted stripping heads. See illustrations below.


Carpenter Model 74

Schaefer ST730 Coaxial Wire Stripper

Schaefer ST730 Coaxial Wire Stripper

Rittmeyer Beri.Co.Max Coaxial Wire Stripper for large cable.

Rittmeyer Beri.Co.Max Coaxial Wire Stripper for large cable.


Crimping coaxial connectors is also a two step process. A terminal is crimped to the center conductor. The connector housing is assembled over the wire and crimped to the insulation. The crimp is normally hex shaped.  Hand or bench equipment for loose piece terminals is used to crimp both the center conductor and connector housing.

Wezag CS30 Hand Crimp Tool

Wezag CS30 Hand Crimp Tool

CS300 Electric Crimper for Loose Piece terminals.

Wezag CS300 Electric Crimper for Loose Piece terminals.


Automated processing of coaxial wire is possible for high volume applications.

RJ11 and RJ45 Cables

Cut and Strip

Cut and strip of RJ11 or RJ45 is possible. This wire is either flat (as pictured below) or round. Flat or radius blades are required to provide the desired nick and scrape free results.

RJ11 Parallel Wire Stripped on Carpenter Compu-Strip 97A.

RJ11 Parallel Wire Stripped on Carpenter Compu-Strip 97A.


Inner conductors and the outer jacket (round cable) can also be stripped stripped using rotary or blade style of wire strippers as illustrated below. Results are application dependent as some wire is irregular in shape.


Carpenter Model 72C


Carpenter Model 78


Modular plugs are loose piece and require a linear action crimp head to crimp (Insulation displacement) modular plugs. The crimp heads are designed to process all leads at one time. Crimping can be done on the CS300 as pictured above or a pneumatic powered crimper like the SSC below.

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Multi-Conductor Cables

Cut and Strip

A cut and strip machine as described for the RJ11/45 wire above can also be used to remove the outer jacket of a multi-conductor wire.  Radius blades may be required for some applications. For larger volume applications, wire processing machines are available where the outer jacket and inner conductors are processed at the same time.



In addition to the outer jacket stripping using a bench top rotary as described above, larger cross sections and longer strip lengths may require a heavy duty wire stripper as illustrated below.



Crimping can be loose piece using the CS300 or SSC as described above or reel form terminals on strip.

Side Feed applicator from Applitek.

Side Feed applicator from Applitek.


As shown by the above applications, there are cross over techniques to these three examples. And by extension, other similar communication wire types. Finding the proper mix of processing methods is important to optimize a specific customer requirement. And that requires a partner that has the broad application knowledge and connections to produce the desired result.  WireProcess Specialties is that partner. We have the resources and partnerships you need. Connect Your Way to WireProcess Specialties.

Methods of Marking Wire and Cable

Marking wire with an identifying number or character has been a necessary part of wire assembly for as long as anyone can recall. Most electrical standards require a mark identifying a specific electrical circuit for tracability in assembly and service

Methods of marking a wire continue to evolve as processing technology improves. New methods are being introduced to compliment existing processing methods which continue to be effective. The result is a wide range of processing options to meet virtually all applications and production volumes.

We will outline some of the more common processing methods and how they are applied in a production environment.


Label mark

Adhesive labels are an effective method of applying an alpha numeric mark to wire. Processing methods include manual from a box or card, labeling guns and semi automatic systems.  Label adhesion can be affected by the type of wire insulation and quality of the label itself.  Permanence can be affected by the above plus the operating environment of the wire. The operating environment can include temperature, humidity and the presence of chemicals or contaminants). Cost of application equipment can range from zero (manual) to high (semi-automated, integrated with a cut only or wire cut and strip machine).

Hot Stamp

Stamprite Machine Hot Stamp Marker

Hot stamp marking is a wire marking process that dates back to World War II.  Hot Stamp marking uses heat type and thermal marking foil to place a mark to the surface of a wire.  The wire is fed through a guide or anvil and the guide assembly lifts up to contact the heated type surface with the foil sandwiched between the type and the wire.  There are two types of hot stamp markers, separate marking type and wheels.  The separate marking type are arranged in the desired number sequence and mounted into a type holder.  In the case of a wheel type of marker, each wheel represents one character and includes the characters generally used (0-9, A-Z, blank and special marks: right and left arrow and hyphen).   Wheel type are quicker to change over and lend themselves better to manual or automatic processing. Actuation is by lever or foot pedal for manual (offline) processing and integrated into a semi or fully automated solution with actuation controlled by the automation system.

Hot stamp marking is less prone to environmental conditions that can affect the adhesion of a wire label.  Some industries specify other marking methods as the mark is imprinted to the surface of the wire using heat and there are concerns about potential damage to the insulation.  But the cycle time is limited and the heat applied is localized so this processing method is acceptable for the majority of applications.

End marking (same or different number on opposing ends of the wire) and continuous (along the length of the wire at a fixed distance) are normal processing types.  Continuous marking does slow down a semi or fully automated wire processing machine as the wire feed must stop during the stamping process.  The number of marks and distance between marks affects processing speed.

The type of thermal marking foil used, the temperature of the type and impression time are critical factors for a hot stamp mark.  The insulation type and wall thickness normally determine the foil, temperature and cycle time. Marking foil normally comes in rolls and is white or black.

Ink Jet

Ink Jet marking is a newer technology relative to hot stamp.  Ink droplets are sprayed onto the wire surface in a pattern to form a character or character string.  Ink jet marking systems are fully programmable and offer more character options than other methods.  These markers can also interface into the operating system of semi or fully automated processing systems. The interface provides programming and processing communication to the marker.  End or continuous marking is possible but It is important to note that without a programming interface between the processing machine and marker, only continuous marking can be processed.  Line speed is quicker than other processes as the process does stop to apply a mark to the wire.

There are a wide variety of pigmented and non-pigmeted inks available to suit a wide range of insulation types.  In addition, chemicals to clean the ink jet head are required to prevent dried ink from clogging the jets. Special handling of ink and chemicals is required and maintenance personnel are normally trained how to properly apply and store chemicals. Ink jet markers are typically dedicated to one type or ink due to the cleaning process required to transition from one ink type to another.

Permanence to an insulation can be a factor as the ink normally does not penetrate below the insulation surface.  The mark can rub off in some environments.  Using pre or post treatment methods such as plasma or UV curing can improve the adhesion of the ink to the wire.

Heat Shrink

Marking to heat shrink and applying the marked heat shrink to a wire is another method.  The heat shrink tube is marked and cut to length on a dedicated machine.  The marked heat shrink tube is applied to the wire manually using the Judco Focus Lite or heat gun.  The mark to the heat shrink is applied using methods such as hot stamp or ink jet.

Laser Marking

CLC Wire Mark

Laser marking is an emerging marking technology.  Line speed is slower than ink jet but suited for continuous marking.  Mark characters and character strings are programmable.  A black mark is the primary color as the character is burned into the insulation surface.  A marking method endorsed by military and aerospace.

Wire Process Specialties provides solutions for processing wire harnesses.  Connect Your Way to WPS to see how we can assist your company in their processing problems.

Processing Heat Shrink with the Judco Focus Lite.

The heat gun has been a standard method of processing heat shrink for decades.  However processing heat shrink tube with a heat gun is generally slow and consumes a significant amount of energy.

The Judco Focus Lite line is a cost effective method of processing heat shrink of various sizes. The energy efficient halogen bulbs operate on demand for fast and efficient shrinking of heat shrink tube. Wire Process Specialties in partnership with Judco Manufacturing has supplied Judco Focus Lite technology to a large number of companies spanning multiple industries to process heat shrink in their assemblies. Faster processing time and lower energy cost are the results of introducing Judco Focus Lite Technology to their assembly processes.

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Several models are available to shrink tube from 5/8″ to 1.5″ OD to 15.5″ in length. Connect Your Way to WPS or visit for more information.

Processing Options for Transformer Manufacturing.

Wire Process Specialties serves many industries that require assembly processes for electrical and electronics.  One industry that WPS has served for a number of years is in Transformers and Magnetics.  WPS supplies a multiple of solutions for the processing of magnet wire and coil winding from simple wire end processing to complex automation for transformer assembly.

Magnet Wire Stripping

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The Carpenter Magnet Wire Stripper series provide cost effective methods to remove the enamel from magnet wire.  Models include the conical wheel 88F shown above for stripping ultra-fine wire down to 48 awg, the 27F with a collet stripping head and available extension wand and the 14B for heavy duty round and rectangular wire.

 Material Cutting

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 The Compu-Cut 42B is a heavy duty cutter for a multitude of uses.  Cutting heat shrink, pvc and fibreglass tube as well as wire and irregular shaped material can be processed with the 42B. The 42B is part of the Compu-Cut machine series which includes the 33 and 36A models.

All consumable and spare parts for Carpenter machines are available through WPS.  For more information on the Carpenter Compu-Cut machines and Magnet wire stripping line Connect Your Way to WPS or visit

 Heat Shrink Tube Processing

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 The heat gun has been a standard method of processing heat shrink for decades.  The Judco Focus Lite line is a cost effective method of processing heat shrink of various sizes. The energy efficient halogen bulbs operate on demand for fast and efficient shrinking of heat shrink tube.   Several models are available to shrink tube from 5/8″ to 1.5″ OD to 15.5″ long.  Connect Your Way to WPS or visit for more information.

Other Processing Options

Applicators and crimping presses for reel fed terminals, terminals and connectors,  quality validating and monitoring systems for crimping, wire marking, wire cut and strip equipment for stranded and multi-conductor wire.

Connect Your Way to WPS to discuss your assembly processes for your products.  We have over three decades of experience serving our valued customers from coast to coast.