Battery Cable Assemblies

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Tapered Post Battery
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Ring to Ring
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Flat/Ground Straps
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Booster Cables
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Fused Battery Cables

As a premier US-based battery cable assembly manufacturer, Precision Cable Assemblies (PCA) leads the way in battery cable assemblies for Original Equipment Manufacturers (OEMs). Our battery cable assemblies are designed to supply a continuous source of electrical power from the battery to peripherals and standard outlying electrical components in a system. Battery power delivery systems must be highly reliable regardless of environmental conditions.

For applications with higher electrical usage, battery cable harnesses are the proper way to organize and secure the many wires such electrical systems sometimes require.  A battery cable harness/assembly secures the wires against the effects of vibrations, abrasions and moisture therefore reducing the risk of an electrical short.

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Tapered Post Battery Cable Assembly

  • Tapered post terminals available in lead, forged bronze, and stamped brass
  • Lead castings available with or without an internal steel reinforcement ring
  • Tin plated brass stamped terminals for wire gauges from 6 through 2 gauge (RoHS Compliant)
  • Lead cast heads for wires ranging from 8 gauge to 4/0
  • Multiple configurations for multiple wires, side leads, 90° Flags, etc.
  • Hardware options for multiple lengths, double headed nuts, and various plating options
  • Heat shrink and covering options tailored to meet your final product needs

Ring to Ring Battery Cable Assembly

  • Copper and brass Options as well as various plating combinations available
  • Open barrel terminals for wire gauges from 8 gauge to 2 gauge
  • Closed barrel lug terminals from 8 gauge through 4/0 gauge
  • Pico style crimp capabilities for power connectors on opposite end of rings where needed
  • Capabilities to crimp multiple wires in the same terminal
  • Heavy duty pull test capabilities for large cables
  • Tin dip capabilities for additional corrosion resistance and increased pull strength
  • Various connector overmolding options
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Flat/Ground Strap Battery Cable Assembly

  • Round and flat wire options for ground straps
  • Lead cast, stamped thimble, lug, and open barrel terminal options
  • Braided copper stranding has no insulation for flexible routing and minimal space impact
  • Lancing lug terminal for removal of paint during connection to chassis

Booster Battery Cable Assembly

  • Co-extruded battery cable wire in 2, 4, 6 and 8 gauge
  • Options for printed and molded stripe marking to differentiate conductors
  • Specialized cutting equipment for circuit slitting and specialized part design
  • Coiling operations directly off cutting equipment
  • Ideal option for small space requirements to transfer battery power through a vehicle
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Fused Battery Cable Assembly

  • IP67 sealed fuse integral to battery cable
  • Multiple form factors for INMIDI, INMEGA, and Maxi fuses
  • Complete cables or sub assemblies allow custom designed fuse options to splice into existing products
  • Temperature options for 105°C and 125°C

Fused Battery Cable Assembly

  • In-line, fused battery cables are a great option when overloads are likely to become problematic. A complete line of in-line fuse holders can be specified as a part of any custom assembly request.
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PCA, a premier battery cable assembly manufacturer, provides battery cable assemblies for a wide range of harsh environment OEM applications such as:

PCA delivers a wide array of battery cable assemblies that are dependent on the client’s application and assembly topologies:

  • Tapered Post Battery
  • Ring to Ring
  • Flat/Ground Straps
  • Booster Cables
  • Fused Battery Cables

With a large number of assembly combinations including wires, connectors, terminals, splices and protective coverings, PCA’s expert electrical, mechanical and industrial engineering staff’s main focus is proper component selection. Each battery and cable assembly is also manufactured to optimize space utilization, cost and quality of customers’ electromechanical system. To ensure proper wire connection, all battery cable assemblies undergo one hundred percent continuity testing.

From prototype to full production possibilities, simple and complex battery cable requirements, and custom molded component capability, PCA is equipped to provide OEMs with optimum end results.

Precision Cable Assemblies continues to be a cable assembly manufacturer that leads the way in conventional and custom battery cable assembly cables.
Contact Precision Cable Assemblies for their expert assistance in design and production of battery cable assemblies.