High Voltage Wire Harnesses
Our Magnetic Pulse Crimping technology (MPC) has become the gold standard to connect terminals to high voltage cables used in the E-Mobility sector.
Our proprietary field shapers crimp the terminal to the high voltage cable in under 100 microseconds. Thanks to the high deformation speed, MPC results in little to no residual forces that would lead to a relaxation of the crimp over time due to repeated thermal cycling. This is vital to high voltage wire harnesses. MPC delivers the most robust connection over lifetime testing, as the integrity of the crimp remains consistent from initial production to the end of the vehicle life, unlike a mechanical crimp.
Our one-stop shops in both the US and France are equipped to provide: rapid prototyping, high volume production, testing and extremely fast delivery times, for a wide range of wire sizes (up to 300mm2).
Products manufactured by our systems
Bmax is the top choice for high voltage wire harness production. With our unmatched capacity, thanks to multiple MPC crimping systems and our in-house capabilities of simulation, micrography and hi-pot testing, we ensure an uninterrupted supply of serial production wire harnesses.
Quality is paramount, with ISO certification and 100% part traceability, ensuring the reliability of our products. We design and manufacture our own systems, maintaining a complete inventory of spare parts, allowing us to perform preventative maintenance and service in-house. With this integrated approach, our operations are seamless and we are able to consistently deliver high quality wire harnesses to you on time.
Over the past 10 years we have developed the most powerful and accurate 3D computational models using unique in-house high-speed deformation characterization of materials to simulate accurately the deformations happening in few hundred millionths of a second.
Co-engineering through simulation can be applied for fast prototyping. This phase is also of paramount importance to freeze part geometry as well as crimping tool design.
We lead the industry with the most advanced manufacturing systems.
As the only supplier in the world with multiple MPC systems in-house, we are equipped to handle high-volume orders efficiently and reliably. Count on us for seamless production solutions tailored to your needs.
With hi-pot testing, micrography, simulation, and in-house equipment service and maintenance, we guarantee precision and excellence at every step. Trust us to manufacture superior products that meet your exact specifications, every time.
Bmax is the top choice for high voltage MPC wire harnesses. With 100% part traceability and ISO certification, we ensure that every component meets the highest standards of excellence. We deliver reliable products backed by rigorous quality control measures.
Our long-term technology roadmap enables our teams to develop production systems featuring increased component lifetimes and reliability, optimized production cycle times, reduced maintenance and user-friendly operation.
Easily retrofittable, all improvements can be integrated in already installed systems, enhancing our Overall Equipment Effectiveness (OEE) over time.
Over the past 10 years we have developed the most powerful and accurate 3D computational models using unique in-house high-speed deformation characterization of materials to simulate accurately the deformations happening in few hundred millionths of a second.
Co-engineering through simulation can be applied for fast prototyping. This phase is also of paramount importance to freeze part geometry as well as crimping tool design.
We lead the industry with the most advanced manufacturing systems.
As the only supplier in the world with multiple MPC systems in-house, we are equipped to handle high-volume orders efficiently and reliably. Count on us for seamless production solutions tailored to your needs.
With hi-pot testing, micrography, simulation, and in-house equipment service and maintenance, we guarantee precision and excellence at every step. Trust us to manufacture superior products that meet your exact specifications, every time.
Bmax is the top choice for high voltage MPC wire harnesses. With 100% part traceability and ISO certification, we ensure that every component meets the highest standards of excellence. We deliver reliable products backed by rigorous quality control measures.
Our long-term technology roadmap enables our teams to develop production systems featuring increased component lifetimes and reliability, optimized production cycle times, reduced maintenance and user-friendly operation.
Easily retrofittable, all improvements can be integrated in already installed systems, enhancing our Overall Equipment Effectiveness (OEE) over time.
Premium Technology
| Magnetic Pulse Crimping | Conventional Crimping | |
| Electrical Resistance | Reduced resistance | Increased resistance |
| Compression Rate | Higher compression eliminates air gaps between strands | Air gaps present with big cable sections |
| Crimp Resistance & Durability | Improved tensile strength with minimal relaxation over time<br> Highest performance with vibration and pull force testing | Higher relaxation over time<br> Limited vibration and pull force resistances |
| Materials Combinations | Use with dissimilar materials (e.g. Cu/Al, Cu/Cu, Al/Al, etc.) <br> Ability to compress almost any tubular copper or aluminum part | Strong limitations<br> Cu/Al crimps do not pass cycling tests |
| Cost | Optimizes component thicknesses, resulting in weight and cost savings <br>Improved longevity of electrical connections resulting in less down time, less maintenance | Higher thicknesses required<br>More down times and more frequent maintenance due to lower longevity of electrical connections |
| Wire Size | Accommodates wide range of wire sizes, in excess of 300mm2 – with no air gaps | Degradation in performance in cables over 70mm2 |
Other Solutions
Pressure Vessels
Our breakthrough Magnetic Pulse Welding (MPW) technology makes it possible to bind materials at molecular level and at room temperature, without fumes or filler material, thus preserving the material’s initial properties.
Complex Parts
Our breakthrough Magnetic Pulse Forming (MPF) and Electro Hydraulic Forming (EHF) technologies make it possible to form metal in motion at extremely high deformation speeds and at room temperature. Bmax thus offers new unmatched production possibilities.
Advanced Packaging
Bmax HPP advanced forming processes do away with nearly every process restriction, enabling you to imagine, design and create shapes that were previously considered impossible – all while using less material and smaller, more efficient, more eco-friendly equipment.
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