Capability · CAP-01
Crimping.
Komax + TE. IPC-A-620 CLASS 3.
Twelve crimp cells under one roof. Komax KMK-08 benches and Alpha 530 fully-automatic lines, with 100% Crimp Force Monitoring on every crimp and four-point cross-sections sampled every four hours. AWG 22 pull strength ≥60 N — 50% over the IPC Class 3 minimum.
≥60N
Pull AWG 22
vs 40N IPC min
±5N
Daily Calibration
Pull-force tolerance
±0.025
Height mm
Crimp height tol
100%
CFM Coverage
All cells
12
Crimp Cells
8 KMK-08 + 4 Alpha 530
AWG 30→4/0
Range
0.05 mm² to 107 mm²
5
Terminal Libraries
TE, Molex, JST, JAE, Hirose
Cpk≥1.67
Crimp Height
Komax Alpha 530
What Crimping Means Here
The Cell Decides
Whether Your Harness
Survives The Field.
Crimping is the single highest-leverage step in a wire harness. The terminal is pennies, the failure is a stranded vehicle. XDPIbuilt the Cavite crimp room around three principles: (1) the machine logs every crimp, (2) the operator can't override the machine, (3) the daily calibration slip is signed before the first piece runs.
Our 12 cells split into three classes: 4× Komax Alpha 530 fully-automatic lines for repeat AWG 18-22 production, 8× KMK-08 bench cells for mid-volume and complex applicators, 12× TE Bench applicators for aerospace M22520-tool crimps. Every cell streams CFM data into the MES; each crimp is barcode-tied to terminal lot, spool lot, operator ID, and the cross-section sample taken closest in time.
Crimping feeds directly into 100% Cirris testing and, where strain relief is required, into TPE overmolding. For HV programs the cells crimp Amphenol RADSOK 8 mm contacts on high-voltage harnesses; for sealed automotive terminals on waterproof harnesses.
Six Crimp-Cell Dimensions
What Makes The Cell
Audit-Proof.
Komax KMK-08 Bench Cells
Eight KMK-08 semi-automatic benches for low-mid volume and prototype crimps. Quick-change applicators for TE MQS, Molex Mini-Fit Jr/Sr, JST PHR, JAE MX. Tonnage to 8 kN.
CRP-01
Komax Alpha 530 Lines
Four fully-automatic Alpha 530 lines: cut → strip → crimp → seal-stuff → tray-stack at 4,500 pcs/hour on AWG 18-22. Cpk on crimp height routinely ≥1.67 (target 0.625 mm ±0.025).
CRP-02
Crimp Force Monitoring (CFM)
Komax Q1202 CFM modules log every crimp force/displacement curve to MES. Auto-reject + lock-out on out-of-band signature. 100% of cells, 100% of crimps. No sampling.
CRP-03
4-Point Cross-Section
Sample crimps cut + polished + photographed every 4 hours per cell on the on-site Mahr cross-section press. Rated for compaction ratio, void %, brush height, bell-mouth — all to IPC-A-620 §10.
CRP-04
Daily Pull-Force Calibration
Mark-10 ESM303 pull-test fixtures torque-wrenched and master-gauge verified at 8 a.m. on every shift. Tolerance ±5 N against the gold-master sample. No green slip — no production.
CRP-05
Plating Compatibility
Tin, silver, and gold-plated terminal contacts. Selective gold (Au-Co 0.8 µm flash) supported for low-current signal terminals; tin plate for power up to 100 A continuous.
CRP-06
Technical Specifications
Crimp Cell Datasheet.
| Wire Range | AWG 30 to AWG 4/0 (0.05 mm² to 107 mm²) |
| Insulation | PVC, XLPE, PTFE, FEP, silicone, ETFE |
| Terminal Vendors | TE Connectivity, Molex, JST, JAE, Hirose, Sumitomo, Yazaki |
| Automatic Cells | Komax Alpha 530 × 4 lines |
| Bench Cells | Komax KMK-08 × 8 stations |
| Manual Cells | TE Bench applicators × 12 stations |
| Crimp Height Tolerance | ±0.025 mm (per IPC-A-620 §10.2) |
| Pull-Force Cal Tol | ±5 N daily, ±2 N weekly master gauge |
| AWG 22 Pull Strength | ≥60 N (vs 40 N IPC-A-620 Class 3 minimum) |
| AWG 18 Pull Strength | ≥110 N (vs 90 N IPC minimum) |
| AWG 14 Pull Strength | ≥220 N (vs 180 N IPC minimum) |
| CFM Sample Rate | 100% (every crimp logged) |
| Cross-Section Frequency | Every 4 h per cell, archived 7 yr per IATF §7.5.3 |
| Cpk · Crimp Height | Typical ≥1.67 on Alpha 530 |
| Throughput · AWG 22 | 4,500 pcs/h per Alpha 530 line |
| Plating Library | Tin, silver, Au-Co flash, selective gold |
Crimp Process Flow
Six Steps. One Barcode.
Wire Cut
Komax Kappa 330 cuts to ±0.3 mm length tolerance, blade-life logged per spool, marker label printed in-line.
Strip
Schleuniger MegaStrip 9650 strips with optical conductor sense; nick-free verified per IPC-A-620 §4.2 on first piece.
Crimp
KMK-08 or Alpha 530 cell forms terminal to ±0.025 mm height; CFM logs F/d curve to MES against gold-master signature.
CFM Verify
Out-of-band signature triggers auto-reject and cell lock-out; operator clears via supervisor PIN. No silent failures.
Pull Sample
Every 50th crimp pulled on Mark-10 ESM303 against AWG-specific min force. Failure escalates to 100% prior-batch sort.
MES Log
Each crimp tied to operator ID, terminal lot, wire spool lot, applicator serial, CFM curve, sample pull result. 7-year retention.
Where Crimps Ship
Six Application Buckets.
Tier-1 Automotive
Yazaki/TE MQS, Sumitomo HW, Molex MX150 sealed terminals for IATF 16949 chassis and dash programs.
EV High-Voltage Battery
Crimped HV terminations to 107 mm² (4/0 AWG) with TE HV280 and Amphenol RADSOK 8 mm contacts.
Medical Patient Cables
Gold-flash signal terminals on AWG 28 stranded silver for ECG, SpO2, multi-parameter monitor cables.
Robotics High-Flex
JAE MX23A crimps on Igus chainflex CF38 — 10 M flex cycles validated per IEC 60068-2-31.
Aerospace MIL-Spec
M22520/2-01 hand crimps with calibrated AFM8 tools, gauge-pin verified per SAE-AS22520.
Industrial Sensor
M12 / 7/8" round-pin contacts, IO-Link compatible, EN 50173 cable certified for EtherCAT/PROFINET.
Founder Note · Mr. Fei Bo Hu
“The first time a Tier-1 customer demoted us, it was over a single AWG 22 crimp that came in at 39 N — one newton below the IPC minimum, on lot 14,000 of a sealed terminal program. After that we stopped trusting periodic pulls and bought CFM modules for every cell. The next 24 audits closed clean. CFM isn't a luxury — it's the difference between losing a program and keeping it.”
— Mr. Fei Bo Hu · President · Xudong Group · XUDONG Philippines
Crimp Engineering FAQ
Six Questions
Buyers Always Ask.
Q.01Why does Crimp Force Monitoring matter more than periodic pull testing?
+
Why does Crimp Force Monitoring matter more than periodic pull testing?
Q.02What's the actual pull-force margin you hold above IPC-A-620 Class 3?
+
What's the actual pull-force margin you hold above IPC-A-620 Class 3?
Q.03Can you crimp customer-supplied terminals or just your stocked library?
+
Can you crimp customer-supplied terminals or just your stocked library?
Q.04How tight is your crimp-height tolerance and how is it measured?
+
How tight is your crimp-height tolerance and how is it measured?
Q.05What stops a fatigued operator from rubber-stamping a bad crimp at the end of shift?
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What stops a fatigued operator from rubber-stamping a bad crimp at the end of shift?
Q.06Do you crimp aluminum conductors for EV battery harnesses?
+
Do you crimp aluminum conductors for EV battery harnesses?
Related Industries
Where The Output Ships.
Real Project Snapshot · Australia · earthmoving-equipment · 2023 → 2024
A Build We Already Shipped In This Lane.
Scenario
An Australian heavy machinery manufacturer requested quotes for multiple custom wire harness models but provided incomplete technical drawings at the initial inquiry stage.
Challenge
Missing critical specifications, including relay models, Deutsch connector models, and Hammond enclosure details, prevented accurate quoting and risked production errors for the 200-piece batch.
Outcome
Achieved full specification lock-down, enabling accurate quoting for 3 sample units and the 200-piece production run, preventing costly rework and material delays.
Anonymized customer detail. Concrete numbers preserved verbatim.
Next Step
Ship A Crimp Sample, Get The Cross-Section Back.
Send terminals + drawing. We crimp 50 pieces on the actual production cell, return cross-section photos, pull-force data and the CFM signature within 5 working days. Quote returned within 12 hours. NDA on file. No obligation.