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3D Printing

Kaliber's 3D printers have brought a new dimension to the Engineering team's capabilities. With the ability to export 3D CAD models as STL files; our Engineering team can now print 3D models for a wide range of applications. These include production/test 'jigs', space models and visual aids for proposals to customers. Our engineering team can now go from a design spec to prototype/space models very quickly. This allows us to prototype custom metal work and check fitment quickly and at no cost to you.

This rapid prototyping allows us to iterate on designs at a low cost and a fast turn-around; if the requirements change we can re-design and re-print, rapidly.

Our 3D printing capabilities are:

Dual Extruders
Variety of material options, such as:
- PLA
- PVA
- ABS
- Nylon

If you are interested in utilising this capabilty we can offer a print only service, or we can also provide a modelling service from our Engineering department.

To enquire about either of these services, please contact us on 01793 533600 or [email protected].

3Dprinter BCN3D

Contact Kaliber

Kaliber Ltd

Unit 2 and 3 Rushy Platt
Caen View
Swindon
SN5 8WQ

T +44 (0)1793 533600
[email protected]

Key Contacts

If you have any requirements that you would like Kaliber to quote for, or you would like to arrange a visit, please contact Neil Mahon:

Sales

Neil Mahon

Mob: +44 (0)7793 009242

Quality Assurance

Quality Management System

Kaliber has incorporated the AS9100 rev D standard as our Quality Management System in order to ensure product conformity and on time delivery to the highest possible standard. Our Quality Management System ensures that all aspects of Kaliber work in tandem and continually improve the processes and procedures’ ensuring the highest standard is set.

Internal Audits

Kaliber has a documented and maintained internal audit procedure. These quality audits verify that Kaliber’s quality activities and results conform to the Quality Management System and current accreditation. All results of the quality audits are documented, implemented and effectiveness of the corrective actions taken are verified.

Supplier Control

Kaliber maintains a list of approved suppliers and a quality history that incorporates on time delivery and frequency of non-conformance. Suppliers are approved based on accreditation, Experian credit level/score, and questionnaire. An internal supply chain management system monitors all suppliers and is evaluated biannually. Kaliber has an established documented procedure to externally audit suppliers based on AS9100 specification or any customer specific criteria.

Material Control

All inward parts are checked against a purchase order to ensure compliance. Non-conforming or faulty goods are quarantined pending supplier investigation. When parts are delivered into stores, the parts are given a unique GRN to allow traceability throughout the parts life. Provisions have been made to provide proper handling and storage to prevent damage and contamination of parts. Kaliber have the capability of handeling ESD components.

Product Control

All product manufactured at Kaliber is controlled by Routecards. This ensures traceability is maintained throughout various processes. Routecards are filled in as appropriate, informing the processes undertaken, the personnel responsible, tooling used, and traceability of material manufactured. Bespoke Routecards are created for products that require special build processes to capture all relevant information. Routecards are scanned once product is despatched to ensure future traceability.

All product is monitored and measured throughout the whole manufacturing process using a bespoke bar-coded scanning system. This is visualised on Kalibers production tracking screens that are used to manage orders throughout the manufacturing process to ensure on time delivery.

Process Control Documents are generated to clearly define the process steps during the manufacturing build.

Test and Inspection

100% Test and Inspection is carried out on all finished product against customer approved drawings, and to any customer requirements and Kaliber set procedures. This ensures that goods received by our customer are fully compliant quality product.

In-process inspection is carried out on all terminations that cannot be inspected at the final inspection stage. This inspection is recorded electronically on a tablet and kept on file for future reference.

5 M.K. test systems with the capacity to test up to 768 points are used to test basic to complex wire harnesses, archiving test results for traceability. Test leads are internally manufactured to mate with product allowing for the best testing conditions possible. Specific functions include:

Continuity measurement of every connection
Detection of short circuits at low voltage
Detection and analysis of crossed wires
High voltage insulation resistance test (maximum 1500VAC and 2500VDC)
Hipot insulation test DC or AC
Capacitance measurement
Distance to short
Single point testing for continuity and short circuits

MS2028C Anritsu RF VNA tester is a 2-port, 2-path, fully-reversing VNA; that measures and displays all S-parameters with a single connection. The Anritsu is used to verify that the coax terminations and coax itself is working within its desired parameters. Specific functions include:

5kHz to 20GHz range
Two-active-port, fully-reversing VNA
Measures all four S-parameters with a single connection
350 usec per data point, ideal for filter tuning
12-term error correction algorithm
Distance Domain option
Time Domain option includes Gated Time Domain, LP Processing, and Phasor Impulse mode

In addition, Kaliber possess the following test and inspection measuring equipment:

High voltage DC testing 10KV for insulation testing
80A PSU unit for full functional testing of product
Multimeters
Oscilloscope
Decibel Meter
Signal Generator

First Article Inspection Record (FAIR)

Kaliber can produce a FAIR on request. FAIR’s are produced to BS EN9102 ‘Quality systems – First article inspection’. Kaliber can produce the FAIR to our own documentation or customer’s internal reports.

Design & Development

Kaliber provide front end design support for all cabling and associated projects. From the simplest of cable harnesses to most complex wiring looms; from power distribution boxes to control boxes. We can build to your existing drawing specifications, or if you require the development of a new design; all requests pass through our Engineering department.

The key to Kaliber's success lies in an expert engineering team, who will:

Produce 2D drawings in HarnWare incorporating a component list and wiring schematic
Create 3D models in Creo Parametric [formerly Pro/E] which can be exported as IGES, STEP, DXF, etc files to most 3D CAD systems (such as Solid Works, Pro-Engineering and Catia). These industry standard formats are also compatible with CAM systems for accurate reproduction of metal work.
Provide input on system design, component selection & harness configuration aimed at reducing costs without affecting performance
Provide reverse engineering for products where drawings are not available

Kaliber provide extensive On-Site Engineering Support worldwide, consisting of but not limited to the following:

Design Consultation
Manufacture of prototypes and installation
Measuring for fit and system installation
On Site Prototype Trial support.
Training

Drawings and/or application requirements are scrutinised to translate these into, firstly, a competitive quotation and then into a process control document for manufacture. Engineer's extensive knowledge of materials, sources and design methodologies allow them to determine the best options to present for your approval. Often judicious selection of materials and source of supply allows significant cost to be taken out of a project.

Manufacturing

Operators

Kaliber have a large team of highly skilled operators with a wealth of experience and knowledge within the industry. Process specific training and support has been given to selected teams of operators to ensure quality and detail is adhered to in an ever changing production environment, thus making all of Kaliber's operators very equipped with the knowledge and skills to deliver quality products.

manufacturing-operators

manufacturing-main

Work Stations

All product is built on individual work stations that have tooling shadow boards and access to a Nedermann extraction system for use when soldering. Bespoke shadow boards are created for specific projects thus ensuring correct tooling is used to comply with demands. Rubber matting is used for builds that require a higher standard of protection.

Training

Kaliber have a designated trainer and training area to continually develop all of our manufacturing operators with regular scheduled training to Industry Standard TE Connectivity COP's, IPC-A-620, manufacturer specifications and internal Kaliber standards.

Kaliber actively analyse internal data to provide operators specific training on areas that require extra attention. This ensures that all of our operators manufacture at a high standard, reducing the risk of non-conformances.

manufacturing-tooling

Tooling

Kaliber has over 1800 tools from various industry leading manufacturers. This contains several automated, hydraulic and pneumatic tooling to increase efficiency and repeatability of build.

Kaliber has a TE3124 thermal transfer printer for marker sleeves; identifying finished product. The 600 dpi print head produces outstanding quality text, barcodes, and graphic images.

Torque Bench

The majority of product manufactured by Kaliber requires applying torque. Kaliber has invested in two industry leading torque analysers, and over twenty torque specific wrenches that break when the required torque value is reached. The torque analysers are used by only a selection of highly trained operators giving high accuracy and repeatability.

A bespoke torque bench enables easy use for operators and ensures product does not get damaged during the torque process.

manufacturing-torque

laying-up

Laying Up Bench

For large cable builds, Kaliber has created a multi-functional bespoke 14 metre laying up bench that makes it easier for our operators to lay up wires, install tubing and measure cables.

Electro-Mechanical Assembly

Kaliber can offer full electro-mechanical assemblies along side our existing core cable harness products. In line with our existing cable harnesses, our electro-mechanical assemblies are produced to a high quality for demanding applications.

box-build-1-cropped

Kaliber's wiring capabilities are a cornerstone of our business. Our experience in complex motorsport open looms gives us a good footing for electro-mechanical assembly.

We're able to produce a range of wired assemblies from simple point to point systems to complex wiring looms. We're also able to incorporate RF coaxial lines within hybrid assemblies.

We're able to incorporate electrical components into the assemblies, such as magnetic toggle switches, relays and transformers. We can also incorporate existing PCB's or design a bespoke solution for you.

Systems produced can be fully function tested as required.

SnipImage

Kaliber's customised electro-mechanical assembly area has been set up to enable maximum efficiency. With rubberised bench tops to protect metal work/components and specialised shadow boards, we're able to manufacture in a low waste environment to our high quality expectation.

switch-box

Kaliber's engineering team utilise Creo Parametric to design custom electro mechanical assemblies. We can incorporate custom PCB designs into this development.

Utilising our 3D printer we're able to rapidly produce prototype enclosures without incurring set up charges from machine shops.

With our 3D design, rapid prototyping and PCB design to supplement our core wiring capabilities Kaliber can offer a full turnkey service for electro-mechanical assemblies.

Tooling & Calibration

Kaliber possess over 1800 Crimp tools, wire strippers, soldering irons, heat guns, torque equipment, Test and Measurement equipment and many other industry related tooling. Kaliber’s bespoke tooling database stores all calibration records, and maintains the lifecycle of tools, indicating when calibration is required.

Kaliber calibrate the majority of these tools in house using the state of the art measuring devices. The following equipment ensures all tools/measuring equipment are calibrated within the parameters set by the manufacturer’s specification:

TorqueLeader ET-Cal

high-torque

The ET-cal 100 Core System measures torque from 4-100 N.m (36-888 lbf.inch) at an accuracy of ± 1%. It has an RS232 interface to allow realtime download of peak torque value and unit of measurement. The ET-cal 100 Core System is used in production as well as calibration. For production it is used to verify that adaptors are being torqued to the correct values as indicated by manufacturer’s specifications. For calibration, it is used to verify the torque wrenches are calibrated within their set tolerances.

Mitutoyo Laser Micrometer

kaliber-microm

Mitutoyo LSM902 ultra-high precision laser scan micrometer can measure as accurately to ±0.05µm. This is used to verify that the diameter of Go/No-Go gauges is within the manufacturers’ tolerance. It is also a very useful tool when checking product to supplier specification to determine non-conformity.

MecMesin Pull Force

mec

MecMesin Multitest 2.5-x has a load cell that performs pull force up to 2500Newtons. It also has the capability to produce graphs. The pull force machine verifies that the mechanical strength of crimped contacts are to the manufacturer’s specification/IPC620.

All master calibration equipment (such as the items above) are calibrated externally by UKAS approved calibration houses. Tools that can not be calibrated internally are sent out externally, normally to the manufacturer for calibration or to a calibration house.

Plant Equipment

Below is a list of plant equipment Kaliber have but not limited to:

6 MK's testing capability 1500 volts AC & 2500 volts DC up to 798 locations 50HZ to 60HZ
10KV tester for lightning strike
Anritsu Site Master VNA Tester for insertion loss on RF cables - distance to fault & S.W.R. Up to 20GHz
Self circulating fume cabinet for tetra etch requirements
Vibration table for removing air bubbles from potting
High temperature oven, 300 degrees centigrade
Comprehensive range of hand tools
2 Automatic and 2 Hydraulic tools for power terminals
6 Pneumatic crimp tools for D38999 and 5015 contacts 0,4,8AWG
High power 80Amp PSU for functional testing
Digital oscilloscope
Digital microscope
2500N in house tensile tester
Mitutoyo LSM69000 Laser Micrometer +/- 0.5 microns accuracy
Static microprocessor controlled analyser for applying torque to backshells with breakaway torque wrenches
MakerBot 3D printer

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