Express Assemblies Ltd

We work with a variety of armoured cables, from single-core aluminium armoured wire to the more common steel wire armour (SWA) with multicore properties. Commonly used for mains electricity in tough environments like underground, ducting, or power networks, these cables provide durability and reliability. Our expertise also covers fire-resistant, solar, rubber, and underground burial cables.

The growing demand for customers to outsource their box build needs has prompted us to dedicate additional time and resources to this area. To provide cost-effective solutions, we currently produce a range of box build products and have developed a flexible wire and cable assembly process that can accommodate any requirement.

Our braided cables are designed for flexible applications and can be shaped into either a flat or tubular form.

By interweaving multiple wire strands, braided wires create a strong, unified conductor that naturally resists interference and corrosion, making them far more durable and reliable than solid core wires.

At Express Assemblies Ltd, we are committed to delivering high-quality braided solutions with exceptional precision and care. We offer copper braid, stainless steel braid, and braided sleeving options tailored to meet any customer requirement.

Express Assemblies Ltd brings extensive experience in wiring and cable loom production and can accommodate any specification.

From simple cut-and-stripped wires to crimped assemblies and more intricate cable looms, we have the expertise to deliver high-quality looms consistently and on schedule.

Our facility is equipped with a variety of specialised looming equipment to enhance our production capabilities.

Whether producing a single unit or fulfilling a large-volume order, every loom undergoes thorough inspection and receives the same meticulous attention to detail and quality craftsmanship that our customers expect.

At Express Assemblies Ltd, we offer comprehensive cable management solutions for all your wire and cable assemblies.

Whether it’s cable ties, flexible conduit, braided sleeving, PVC tubing, pluggable or screw-type terminal blocks, cable glands, or rubber grommets, we leverage our extensive experience to deliver cost-effective and innovative solutions tailored to your cable management needs.

Just as crucial as cable design and manufacturing is the proper marking and identification of wires and cables, a step that is often overlooked.

Every electrical product requires some form of identification, and effective cable management frequently depends on operators using markers to quickly detect issues and carry out maintenance.

By employing clear and legible cable markers, wires and cables can be easily located even within complex assemblies, providing a convenient, time-saving solution that simplifies maintenance and enhances overall project efficiency.

We can supply products manufactured according to customer drawings, samples, or specifications.

In addition, we offer a service to provide custom alternatives aimed at reducing costs. Whatever your requirements, we can adapt our processes to meet your exact needs.

Our bespoke wire and cable sets are designed to deliver exceptional performance, unmatched quality, and consistent reliability. We work with a wide range of wire and cable types, offering essential interconnect solutions.

With hundreds of custom cable assemblies and bespoke wire sets produced daily, our business and product portfolio continue to grow steadily.

Our LSZH (Low Smoke Zero Halogen) products are designed for installations where minimal exposure to toxic fumes or smoke is critical in the event of a fire.

They are particularly suited for confined or poorly ventilated environments, such as underground railways or lift shafts.

Unlike PVC, the most common cable jacket material, LSZH wires and cables do not produce harmful black smoke, toxic fumes, or acid gases when exposed to high temperatures.

By offering LSZH wire and cable assemblies, we fulfill our commitment to corporate social responsibility, providing safer materials for users while reducing potential environmental impact.

At Express Assemblies Ltd, ribbon cables are a core part of our manufacturing expertise.

With demand steadily increasing, high-quality ribbon cable assemblies are essential to ensuring the success of many electronic products.

A ribbon cable consists of multiple conductors running parallel along a flat surface, allowing it to connect numerous internal peripherals across a range of electronic applications.

These cables are typically terminated with IDC (insulation displacement) connectors, enabling mass termination and improved signal integrity for electronic devices. This configuration is the industry standard for ribbon cable assemblies.

At Express Assemblies Ltd, we specialise in flat grey ribbon cables featuring a red stripe for clear orientation and to prevent reversed connections.

Our ribbon cables are manufactured with a 0.05-inch (1.27mm) pitch and 28 AWG wires, then crimped with a two-row IDC connector with 0.1-inch (2.54mm) pin spacing, ensuring precision and reliability in every assembly.

Soldering has played a transformative role in the electronics industry.

At Express Assemblies Ltd, we employ precise soldering and de-soldering techniques to ensure all products are manufactured with the highest level of accuracy.

We recognize soldering as a critical skill in the production and assembly of electronic devices. Over the years, we have honed our expertise to create durable, reliable soldered joints capable of performing in demanding environments.

Our products use both tin-lead and lead-free solder, all compliant with regulatory standards and providing dependable termination solutions.

We maintain strict standards and acceptance criteria for all soldered connections, ensuring each assembly meets the required electrical and mechanical performance for high-quality results.

Similarly, our tinning operations follow the same rigorous approach. Using multiple solder baths, we coat prepared wires with molten solder to enhance their solderability.

Tinning is applied to wires that will be soldered to components such as PCBs or other solderable surfaces. Like crimping, this process ensures wires remain intact, preventing splaying or damage while providing a reliable method of wire termination.

At Express Assemblies Ltd, we offer a range of products that require solid or single-core wire preparation.

Using our automated wire cutting and stripping machines, we can produce wires to any specified length and strip them as needed.

Single-core wires provide a strong, durable connection, though they are less flexible than multicore alternatives.

Depending on your application, Express Assemblies Ltd can adapt its production processes to meet any solid-core cable requirement. We also maintain a ready supply of various solid single-core cables for immediate use.

At Express Assemblies Ltd, we recognise that each wire and cable assembly serves a distinct purpose. To meet these needs, we provide specialised cable assemblies as part of our product offering. We support a wide range of industries—including medical, automotive, military, and defence—where bespoke materials and components must meet rigorous quality standards. Thanks to our strong procurement network, we are able to source precise specifications to match customer requirements. With our products already applied across diverse sectors, we take pride in our ability to adapt and deliver solutions for emerging and highly specialised markets.

Our manufacturing operations are highly competitive, adaptable, and efficient, with full customisation to accommodate any product specification or customer requirement.

Express Assemblies Ltd is ISO 9001:2015 certified, reflecting our adherence to the highest quality standards for manufacturing. We have also invested significantly in infrastructure, resources, and equipment to ensure every product benefits from a premium manufacturing process.

Through continuous process optimisation, we have achieved notable time savings and cost reductions, while enhancing overall productivity and profitability.

Our mission is to deliver the highest level of customer service, which sometimes involves collaborating on aspects of a customer’s product design.

While we are not a design house and do not have 3D CAD or engineering software on site, we provide valuable insight into the practical aspects of product design, offering constructive feedback for development and realization.

Each customer product design is carefully reviewed through a thorough and precise analysis process, ensuring we fully understand your requirements and help achieve a successful final product.

Customer satisfaction and meeting their requirements are our top priorities.

We strive to deliver outstanding customer service, showcase expertise in our products and services, and provide prompt, efficient responses to all enquiries.

We recognise that product schedules are often time-sensitive.

At Express Assemblies Ltd, our dedicated product review and quotation team aims to respond to enquiries within 24–48 hours.

All quotations are competitive and clearly outline the required services and labor costs. We can work with customer-supplied components, charging only for assembly, or provide full build quotations, including expected delivery dates and lead times.

We also provide prototyping and complimentary sample units.

Once a quotation is officially approved, we can supply free sample units for customers to test in their final product application before full production begins.

This allows any adjustments or changes to the original specifications to be made without disrupting the production line.

Effective communication with our customers is essential.

Upon receiving a purchase order, we promptly acknowledge it, providing key details such as product part numbers, purchase order references, descriptions, pricing, delivery dates, and lead times.

Once an order is completed, we send an order confirmation along with a dispatch or shipment notification. This includes details of the purchase order, items enclosed, courier information, number of packages, shipment dimensions and weight, and tracking numbers for easy reference.

Maintaining clear and consistent communication ensures a seamless process, helping us transition from a potential supplier to a trusted, repeat partner.

We maintain an extensive inventory of materials and components.

As a leading wire and cable manufacturer, Express Assemblies Ltd understands the importance of sourcing the right components for any customer project or product design, and we can obtain nearly any item required for a wire or cable assembly.

Through strong relationships with top industry suppliers, we are able to offer cost-effective solutions to our customers.

For bespoke or specialized cable assemblies, we strive to adhere closely to the original drawings and specifications. Where cost savings are possible, we may suggest equivalent or alternative components, demonstrating our commitment to meeting customer needs.

Our ready-to-use stock includes everything from equipment wire, tri-rated cable, and mains cable to resistors, capacitors, fuses, fasteners, ferrite cores, crimps, and packaging solutions, allowing us to handle virtually any product specification.

If an item is not in stock, we can typically replenish it by the next day and can provide stock-holding services upon request, with advance notice.

At Express Assemblies Ltd, we take pride in offering a wide range of ordering options.

We can handle everything from single-unit orders to just-in-time deliveries, scheduled orders, make-to-stock arrangements, and purchase forecasts.

By closely monitoring and managing our inventory, we ensure a more efficient and proactive production process that meets our customers’ needs.

We maintain a range of test equipment to ensure the performance of our wire and cable assemblies.

At Express Assemblies Ltd, we adhere to strict quality management principles, carrying out routine process validations and product verifications on-site to ensure manufacturing practices consistently meet product requirements.

Additionally, we offer product testing as a service, using our equipment to monitor and measure processes or products for validation and verification, ensuring full conformity with specifications.

At Express Assemblies Ltd, we believe that product presentation is just as important as manufacturing and production.

We take great care in packing our assemblies, using sustainable, eco-friendly, and recycled materials wherever possible.

This approach not only helps reduce our carbon footprint but also reflects our commitment to quality and environmental responsibility.

At Express Assemblies Ltd, we are committed to delivering high-quality products on time, every time.

We focus on providing rapid order turnaround and prompt delivery to our customers.

To meet these expectations, we have invested heavily in a reliable logistics network capable of handling local, national, and international shipments.

With a strong global presence, we regularly deliver products worldwide using approved courier services at highly competitive rates, often lower than most competitors.

In addition, we also utilise our own transport to ensure timely deliveries, demonstrating our dedication to getting your products to you when promised.

At Express Assemblies Ltd, our approachable finance and accounts team is available to assist with any financial queries.

They manage daily bookkeeping, VAT, payroll, banking, and bulk supplier payments.

Using electronic accounting systems, we provide customers with clear invoicing, statements, and credit control reports.

Credit accounts are offered to all customers, with terms and conditions outlined in the sales contract. Credit limits are applied to manage cash flow and minimise risk, but we remain flexible and can discuss increasing limits to meet customer requirements.

Express Assemblies Ltd provides repair services and complete reworks for faulty wire and cable assemblies. We focus on fast turnaround times and reliable solutions, delivering results that meet customer needs regardless of the complexity involved.