Benefits of Electrical Function Integration

Replace separate wiring looms.

Add functions, save space and weight and make safer, more durable products.

Electrical Function Integration (EFI) is how we describe our robotic manufacturing processes that add electrical components and wiring to complex shapes made from metals, polymers or ceramics instead of having to have a separate wiring loom.

EFI has advantages beyond simply automating manufacture of wiring harnesses.

Freedom to add more function

Products are differentiated on functionality, which usually requires electrical connections.

Freedom to add more function

Separate wiring looms must withstand manual handling so are heavy and space hungry. They can only be placed where it is possible to assemble them into the final product, which often requires more manual handling. All this limits the functions that can be added.

 

With Electrical Function Integration the components, wires and, conductive tracks needed to add function to your product can be placed exactly where they are required and retained there. As a result the wires and other components are not subjected to the same mechanical stresses during manufacture or assembly into the end product.  This means that wiring can be optimised for electric function only, saving space and weight and/or allowing more functions to be added.

Safer products

Failure in wiring primarily occurs due to over-stretching, over-stressing and chafing.

EFI protects electrical connections from damage.

Safer products

Wiring harnesses have to be flexible and long enough to allow for manufacture and final assembly. This means that they are vulnerable to mechanical and environmental damage, throughout their production and use in the final product.

 

EFI provides a means of anchoring wires and connectors to give protection from mechanical and environmental degradation. Damage is eliminated from manufacturing and through the service life of the component. Wires cannot chafe against each other, and for harsher service 3D polymer additive over-moulding is possible. As a result the final product is safer and more durable.

Fully digital manufacture

Enables optimised products made repeatably.

Fully digital manufacture

At present wiring is not fully modelled. Neither the final product nor its manufacturing can be fully optimised.

 

Automation through Electrical Function Integration means that finite element analysis of the complete product can be undertaken. Electrical function can be fully designed and specified and manufactured repeatably. As a result, quality control is enhanced and measurable and a true digital twin can be created of every individual part made.

 

Design to manufacture translational errors are eliminated, and product development cycle times can be shorter with rapid prototyping.

Freedom to add more function

Products are differentiated on functionality, which usually requires electrical connections.

Freedom to add more function

Separate wiring looms must withstand manual handling so are heavy and space hungry. They can only be placed where it is possible to assemble them into the final product, which often requires more manual handling. All this limits the functions that can be added.

 

With Electrical Function Integration the components, wires and, conductive tracks needed to add function to your product can be placed exactly where they are required and retained there. As a result the wires and other components are not subjected to the same mechanical stresses during manufacture or assembly into the end product.  This means that wiring can be optimised for electric function only, saving space and weight and/or allowing more functions to be added.

Safer products

Failure in wiring primarily occurs due to over-stretching, over-stressing and chafing.

EFI protects electrical connections from damage.

Safer products

Wiring harnesses have to be flexible and long enough to allow for manufacture and final assembly. This means that they are vulnerable to mechanical and environmental damage, throughout their production and use in the final product.

 

EFI provides a means of anchoring wires and connectors to give protection from mechanical and environmental degradation. Damage is eliminated from manufacturing and through the service life of the component. Wires cannot chafe against each other, and for harsher service 3D polymer additive over-moulding is possible. As a result the final product is safer and more durable.

Fully digital manufacture

Enables optimised products made repeatably.

Fully digital manufacture

At present wiring is not fully modelled. Neither the final product nor its manufacturing can be fully optimised.

 

Automation through Electrical Function Integration means that finite element analysis of the complete product can be undertaken. Electrical function can be fully designed and specified and manufactured repeatably. As a result, quality control is enhanced and measurable and a true digital twin can be created of every individual part made.

 

Design to manufacture translational errors are eliminated, and product development cycle times can be shorter with rapid prototyping.

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