Phoenix Dynamics Ltd - Phoenix Dynamics

Phoenix Dynamics Limited is a leading design, development and manufacturing company specialising in electrical cable assemblies, wiring harnesses, power leads, control panels and electro-mechanical assemblies.

We have a wealth of experience supplying to a wide range of market sectors where many of our products find application in equipment in some of the harshest environments in the world. 

Our customers range from small privately owned companies to large multi-national and overseas organisations in markets as diverse as Defence, Energy, Industrial, Motorsport and Rail. Our production quantities are as diverse as the markets we serve with volumes ranging from a 1off prototype through to repeat orders of 100’s of units per week, all manufactured to the high quality levels our customers expect.

Phoenix Dynamics can manufacture a wide range of cable assemblies and wiring harness products in a variety of styles and finishes including heat-shrink, conduit tube, braid, woven cables, ribbon cables, tape and tie-wrap. Ruggedisation of cables is one of our major strengths and we have become experts in fully sealed, potted and over-moulded assemblies. Temperature extremes, water ingress and mechanical endurance are all design challenges we regularly face since many of our products find application in equipment operating in the harshest of environments.

We can offer assemblies made using bespoke multicore cables giving the customer the precise number, type and size of cores to suit their particular requirement. These machine built cables give the customer greater consistency of product with precise lay-up of conductors with even tension on all cores. Options include the addition of fillers for roundness and flexibility, EMC braids woven in situ to maximise shielding effectiveness and in the case of the extruded jacket, control over wall thickness and concentricity. All these elements combined with improved handling characteristics give higher performance levels than traditional hand built cables.

To compliment the core business of cable assembly, Phoenix Dynamics offer an electro-mechanical assembly and integration service including control panels, box assemblies and sub-assemblies along with any supporting brackets and fasteners.

These assemblies may contain a variety of electrical components including PCBs, switches, bulbs, LEDs etc.

Phoenix Dynamics will manage the entire supply chain from sourcing the metal work through to delivery of the final assembled product. With support from our expert supply chain we can offer assemblies made up from various standard and specialist materials, whether it be painted or plated metals or one of many thermoplastic materials.

Phoenix Dynamics manufacture large quantities of heavy duty cables such as Power Leads, Earth Leads and Battery Cables with cross-sectional areas up to 120sqmm. These high power cables are often used as the main electrical feed into a product of which all other internal circuits depend upon. To ensure their high quality we have invested in a calibrated pull-off measurement facility to guarantee their performance.

Phoenix Dynamics currently manufacture and supply a range of lighting assemblies for trailers and trucks etc. These assemblies contain all relevant lamps, wiring looms, mounts and brackets and are usually provided in kit form to assist the customer’s final assembly.

There are occasions when the optimum solution to a problem is just not available as a standard catalogue item.  Phoenix Dynamics have the capability and the experience to help when such occasions occur. We have developed a wide range of bespoke components to solve specific design issues and have either manufactured the parts ourselves or worked in partnership with our supply chain to  bring these concepts to life.

Examples of which are moulded components and bespoke connectors and backshells.

All products are fully tested using Phoenix’s own brand VALIDATA III® test system. This system has been designed and built to provide full electrical integrity testing and combines both high voltage and high current capability. The test equipment has been used successfully for the demanding test criteria of aircraft, aero engine and missile wiring systems.

Phoenix Dynamics’ demonstrated expertise in product innovation has led to customers asking for our support in the original design of new cable assemblies and other related products. Phoenix Dynamics can manage all aspects of the design cycle from early conceptual ideas through to a final technical design package or manufacturing drawing ready for production.

We can also carry out a full test programme as defined by the system specification to validate prototype harness design and then first off articles from a production run.

Typical harness tests include:

• Thermal cycling
• Mechanical handling
• EMC shielding effectiveness and immersion

Any deterioration in properties identified will be assessed in terms of changes to electrical parameters and fit for use.

Whether the attributes of the design brief be robustness, serviceability, weight reduction or environmental protection, Phoenix’s ability to engage technology to solve problems makes us the design partner of choice.

Phoenix Dynamics are happy to support the customer in all stages of their build programme from the initial prototype through to volume production. Whether it is a Phoenix designed wiring harness or built to print to a customer's exact standards you can be sure of exceptional finished build quality every time.

Products are assembled, tested and inspected within manufacturing cells dedicated to either a product type or to a customer project depending on the requirements with the process following lean manufacturing principles at every stage. A customer focused cell can be ring fenced for security if required and in effect run as an extension of their own manufacturing process.

More information on Manufacture / Build to Print

Phoenix Dynamics offers a project management service to assist in the delivery of complex customer programmes. Structured NPI and AQP techniques ensure timely completion of all key stages of a build programme. All stages are closely monitored and managed with regular milestone updates.

Phoenix Dynamics has vast experience in supporting products throughout their lifecycle and can provide a survey and repair service to keep products in operation when time or cost restrictions do not allow replacement. Since many of our products are in operation for periods of decades we have become experts in resolving obsolescence issues on components that were once specified. We also offer a reverse engineering service to manufacture parts where the original source may no longer be available.

Phoenix Dynamics has experience in supporting defence projects through that critical phase where prime contracts finish and the spares demand begins. We have developed and put in place systems with our customers to ensure that end-user demands are met at an acceptable cost. Generally thre is a balance to be struck between finished goods on the shelf, work in progress and component stock.

For many of our customers we are now doing more than simply supplying a wiring loom. We often package or assemble a number of diverse parts together to form work packages such as upgrade or modification kits.

This value added service can help reduce overall costs for the customer by reducing the number of suppliers, inventory levels and administration costs whilst at the same time increasing efficiency on their assembly lines or follow on processes.

Phoenix Dynamics currently serve a wide range of market sectors at both OEM level and sub-tier suppliers. We have particular experience in the Defence and Energy sectors but also support Industrial, Rail, Specialist Automotive (including Motorsport) and Security.

We are actively involved in a variety of military programmes with the UK MoD, US DoD and Defence Prime Contractors in support of Artillery, Land Vehicles, Mine Clearance and Naval applications. A significant quantity of this product is now exported and we have great experience of the rigorous procedures and approvals associated with this activity.

We are the number one supplier of cable assemblies to a major player in the Renewable Energy market with a strong focus on wind turbine power generation. We support a number of Rail projects with cable assemblies for both trackside and rolling stock ancillary equipment and also support numerous other industries with cable products on a long list of miscellaneous applications.

A recent development has been to move into the Motorsport Industry. Our expertise in the design and build of high performance wiring looms is proving to be a valuable asset and has lead to a number of exciting opportunities within this sector.