Wire Services & Wire Harness Assembly
Cusack Electronics delivers precision wire services covering wire cutting, stripping, wire crimping, wire termination, and complete wire harness assembly. From single prototypes to production runs, we handle custom cable assemblies with certified crimps, continuity testing, and full traceability.
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Who We Are
Creative Design
Uncompromised Quality.
As a leading electronic contract manufacturer, Cusack Electronics brings together engineering expertise, in-house fabrication, and a passion for innovation, helping clients launch successful products from concept to mass production. We operate under the guiding principle: “Help people help themselves.” We value long-term partnerships and apply our deep love of electronics to every project we take on.
- Schematic & PCB design, firmware dev, complete electrical engineering from concept to tech-files.
- In-house SMT, through-hole & selective solder — full PCB population using production-grade equipment.
- CNC milling, powder coating & UV printing — professional enclosures and finished assemblies under one roof.
- Wire harnesses & full product builds — from individual PCBs to completely finished boxed products.
Our Services
9 In-House Capabilities
Everything your product needs — designed, built, finished, and shipped — all from our West Michigan facility. No outsourcing, no delays.
Schematic & PCB Design
Altium Designer
KiCad
BLE / WiFi
Eagle CAD
IoT Ready
Multi-Layer
Firmware & Software Development
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
3D Modeling & Mechanical Design
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
PCB Population & Assembly
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
CNC Milling & Machining
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Powder Coating
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Full-Color UV & Direct Printing
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Wire Harnesses & Cabling
Custom wire harness design and manufacturing — from simple 2-wire cable assemblies to complex multi-conductor harnesses with connectors, terminals, heat shrink, and labeling for production builds.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Full Product Assembly
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
How It Works
Our Design & Build Process
01
Discovery & Requirements
We listen deeply to understand your product vision, target market, technical requirements, and production goals. We define scope, schedule, and budget up front.
Consultation
Feasibility Study
NDA Available
02
Concept & Schematic Design
Schematic Capture
BOM Generation
Circuit Simulation
03
PCB Layout & 3D Modeling
Gerber Files
3D CAD
DFM Review
04
Firmware Development
Embedded C/C++
Unit Testing
Source Code Delivery
05
Prototyping & Testing
Functional Testing
Debug & Iteration
Client Approval
06
Production & Full Assembly
Once approved, we move into production runs — SMT/THT population, wire harnesses, CNC enclosures, powder coating, UV printing, and full product assembly with QC inspection.
Production Run
QC Inspection
Packaged & Shipped
Technical Specifications
Design Capabilities at a Glance
Our in-house equipment and engineering team handle a wide range of technical demands across all service areas.
PCB & Electronics Design Specs |
|
|---|---|
| Machining Envelope | Up to 40" × 20" × 20" (VMC), 60" × 30" × 30" (HMC) |
| Minimum Tolerance | ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request |
| Surface Finish | Ra 32 μin standard, Ra 16 μin or better achievable |
| Hole Diameter Range | 0.040" to 4.000" with drill bits, reamers, and boring bars |
| Thread Sizes | #2-56 through 1"-8 UNC/UNF, metric M2 through M24 |
| Materials Supported | Aluminum, steel, stainless, titanium, brass, copper, plastics |
| Axis Configuration | 3-axis, 4-axis, 5-axis milling |
| Batch Sizes | 1 piece prototypes to 10,000+ production runs |
| Inspection Equipment | CMM, optical comparator, micrometers, calipers, profilometer |
| Standards Compliance | ISO 2768, ASME Y14.5, ISO 1302 |
Our Services
9 In-House Capabilities
Everything your product needs — designed, built, finished, and shipped — all from our West Michigan facility. No outsourcing, no delays.
Everything Under One Roof
Design, PCB population, CNC machining, powder coating, UV printing, and full product assembly — all done in-house at our West Michigan facility. Fewer handoffs means faster delivery and tighter quality control.
Long-Term Partnership Model
We operate by the principle "help people help themselves." We invest in understanding your product deeply and become a true technical partner — not just a vendor taking purchase orders.
Scalable from Prototype to Production
Start with a single prototype, iterate quickly, and scale to production runs of 10,000+ units — all with the same team and quality standards. No re-quoting, no new supplier onboarding.
Music Industry Pedigree
We own two professional audio brands (Cusack Music and Mojo Hand FX) and design for many others. This real-world product development experience makes us far more than a typical contract manufacturer.
IP Protection & NDA
Your designs, schematics, and firmware stay yours. We sign NDAs on request and treat all client IP with strict confidentiality. We never share or reuse your proprietary designs.
100% American Manufacturing
Every product we build is designed and manufactured in the USA. No offshore outsourcing, no quality surprises. You get direct communication with the engineers building your product.
Software & Equipment
Tools We Use
Altium Designer
PCB layout & schematic
KiCad EDA
Eagle CAD
SolidWorks
Fusion 360
LTspice
OrCAD
In-House SMT Line
Markets We Serve
Industries We Design For
Professional Audio
Industrial Automation
IoT & Connected Devices
Consumer Electronics
Automotive & Motorsport
Test & Measurement
Featured Projects
Ready to Design & Build Your Next Product?
- Free initial consultation, no obligation
- NDA available for IP protection
- Prototype to production, all under one roof
- 100% USA designed & manufactured