From raw polymer to certified cable assembly — 195 production lines across China, Malaysia and Singapore, governed by four global quality systems.
Custom Engineering
Engineered for the world’s most demanding industries.
End-to-End Process
From customer brief to coiled, certified cable.
Specialty cable is not catalogue work. Every build starts with a conversation in Singapore and ends with a release-tested reel — eight stages, fully traceable, with customisation engineered into the front half.
95% of Tri Wire builds are made-to-spec. Conductor stranding, insulation chemistry, shield architecture, jacket compound and reel format are all customer-defined inputs — not fixed SKUs.
STAGE 01
Customisation
DFM & Cable Design
Customer engineering team meets Tri Wire’s Singapore engineers. Electrical, mechanical, thermal and environmental requirements are scoped against application data — then translated into a buildable BOM: conductor AWG and stranding, insulation chemistry, shield architecture, jacket compound, colour, print marking. CAD cross-sections issued for sign-off.
STAGE 02
Customisation
Prototype & First-Article Inspection
Short production run for customer validation. Electrical, mechanical and environmental tests executed against the approved spec sheet. FAI report issued. Design iterations folded back into the BOM before tooling is locked for series production.
STAGE 03
Production
Conductor Stranding
Bare or tinned copper drawn to spec AWG, then bunched on single- or double-twist machines (55 machines installed). Lay length, direction and tension tuned to flex-life targets. Litz wire construction available for high-frequency builds.
STAGE 04
Production
Insulation Extrusion
Conductor passes through one of 27 insulation lines — standard PVC/PE, thermoplastic TPU/TPE, or fluoropolymer (PTFE, FEP, PFA, ETFE) for medical and high-temperature builds. Wall thickness, concentricity and capacitance monitored inline.
STAGE 05
Production
Cabling, Shielding & Jacket
Insulated cores assembled on tubular and planetary cablers. Tinned-copper braiders, spiral shielders and foil-tape lines applied per spec — EMI shielding, mechanical reinforcement, aramid strength members. Outer jacket extruded on one of 50 lines: medical-grade TPU, chemical-resistant TPE, flame-retardant PVC or fluoropolymer skin. Print marking and stripes applied inline.
STAGE 06
Production
Test, Mark & Ship
Final electrical tests — continuity, hi-pot, capacitance, attenuation — against the customer spec. Dimensional and visual QC. UL, IATF and ISO 13485 release procedures applied. Reeled, labelled, lot-traceable, shipped from China or Malaysia.