Q5D Technologies and KYOCERA AVX have expanded their collaboration to support the development of fully automated wire harness assembly, unveiling plans to jointly design custom insulation displacement connector (IDC) solutions tailored for robotic manufacturing.

The partnership builds on three years of joint work focused on adapting IDC technology for integration with Q5D’s robotic wiring systems. The latest phase centres on developing connector designs specifically optimised for automated termination, with the aim of improving efficiency and repeatability in harness production.

Q5D’s five-axis robotic platforms are designed to address one of the more labour-intensive processes in manufacturing: wiring harness assembly. These systems are used across sectors including automotive, aerospace, household appliances and industrial equipment, where manual wiring remains common. By contrast, IDC technology allows wires to be inserted and connected without the need for traditional crimping tools, making it more compatible with automated processes.

Unlike conventional crimp-based connectors, IDC contacts can be mounted to a surface and terminated from one side. This enables robotic systems to position wires, secure them, and complete the connection through a controlled pressing action, reducing reliance on manual intervention.

Over the course of the collaboration, the two companies have conducted a series of evaluation programmes using existing IDC products alongside a range of customer-defined wiring specifications. These tests have included conductors typically ranging from 12 to 32 AWG and applications covering low-power signals through to currents of around 20A. The work has focused on achieving consistent cold-weld terminations and ensuring reliable performance under conditions such as mechanical shock and vibration.