Our team is completely honored to be recognized by the Small Business Development Center (SBDC) at JCC. 
We extend a huge thank you for all of their help! 

SBDC Success Story: Falconer Electronics


September 5, 2019

Courtney Curatolo, PhD, Director of SBDC at JCC

Falconer Electronics, a manufacturer of ground straps, commercial power strips and wire harness assemblies founded in 1985 in Falconer, New York, experienced robust sales growth since engaging with the Small Business Development Center (SBDC) at Jamestown Community College (JCC). To provide a snapshot of the powerful impact that the SBDC marketing plan delivered to Falconer Electronics, website traffic increased by 1000% from November 2017 through Jan 2019.  The results have been truly amazing.  “This new website traffic has opened doors that previously never existed for Falconer Electronics” according to Founder and President Roger Hall. In addition, the staff at Falconer Electronics increased by 9 full time employees in that time frame as well.  These new employees are a direct result from the impact of working with the SBDC team.

In 2016, the SBDC at JCC invited Falconer Electronics to participate in an exciting Social Media Marketing initiative.  Partnering with the SBDC to implement a new internet marketing strategy was a welcomed opportunity. At that time, Falconer Electronics was struggling with figuring out digital marketing and obtaining new customers.  The SBDC also supported Falconer Electronics with hiring a Social Media Intern provided by JCC. Bringing in a talented student intern served as a valuable resource while implementing this new internet marketing plan.

Since August of 2018, Falconer Electronics has received over 130 qualified leads from new potential customers. These new leads either submit product CAD drawings or a Request for Quote (RFQ) directly through the company website.

In addition, due to the drastic increase in website traffic, Falconer Electronics decided to create their own proprietary software that allows customers to receive an instant quote or estimate.

  1. The Instant Ground Strap QuoteBuilder:

  2. The Wire Harness Estimator:

Each software program has been a tremendous success for Falconer Electronics. These new software tools generate leads that come from engineers, new product developers and product procurement specialists.  Numerous Fortune 500 companies and publicly traded companies as well as mid-tier manufacturers and OEM’s now contact Falconer Electronics on a consistent basis.

The SBDC Internet marketing program also provided an avenue to market finished goods direct to end users on the Falconer Electronics website.  Once the SBDC marketing initiative was complete, Falconer Electronics gained the knowledge and confidence to create an eCommerce store.

“Without the assistance from the SBDC Social Media Marketing Initiative, this sheer quantity of new customer engagement would have never taken place,” says Hall. “We not only have converted dozens of these leads into paying customers, we are now also seeing repeat orders from customers.”

Selling finished goods was new to Falconer Electronics since they served the market strictly as a custom manufacturer dating back to 1985. The company is now also selling their Ground Straps and Commercial Power Strips on Amazon.

According to President Roger Hall, “the SBDC at JCC is an invaluable resource for our local business community.” 

Click here to view the article on the SBDC website: SBDC Success Story: Falconer Electronics

An American business purchasing products from foreign countries certainly creates many challenges. When working with a foreign company there can be some difficulty with achieving a positive final outcome.

A few issues that can arise include:

  • Misunderstandings due to language barriers and “lost in translation”
  • Challenges with manufacturing products
  • In addition, the difficulty of repairing products 

Communication Issues in Doing Business Abroad 

Doing BusinessWorking with other countries opens the door for communication gaps. This could be due to a simple misunderstanding. On the other hand, the gap could be caused by “lost in translation”. In other words, language barriers or translation challenges that create unwelcome errors. 

Whether the communication is happening through emails or even over the phone, barriers exist. These communication barriers can prevent the foreign company from fully understanding the needs of the American company.

They can also cost the American company more money on materials. This can happen due to different terms of products or even various means of measurement. Sometimes in these cases, the foreign company may make assumptions. However, if those assumptions are incorrect, the entire product could be wasted. It can be difficult to bridge the gap of communication which costs the company significant time and money.

Manufacturing Issues

Another issue that can go along with communication includes problems with the actual manufacturing process. If there is a gap in communication there is also a chance that there will be difficulties instructing the foreign country on how to manufacturer the product. If instructions are misunderstood or they have incorrect translations, the foreign business will have a difficult time producing the product.

When there is an issue with manufacturing, there is often a need for a representative from the American company to go on location to the foreign company. Travel costs run high. Especially when traveling abroad. In addition, traveling will also take up useful time that could be utilized for other projects.

Commonly, you can trace manufacturing issues back to communication. However, with no communication gaps, both companies would be able to achieve success through all the stages of production.   

Repair Issues

Another issue that can come from poor communication is damage. Some damage may occur during manufacturing or shipping. If the foreign company attempts repairs, the situation could become worse. Especially, if there was confusion with producing the product in the first place. Furthermore, it is difficult to troubleshoot a problem when they are not in physical proximity.

A company cannot plan for repairs on goods damaged during shipping. There will have to be replacement of pieces when damage occurs. There is no guarantee that repairs will actually fix the problem. However, even if the repairs provide a short-term solution, both parties need to focus on a long-term fix as well.  

Communication, manufacturing, and repair issues are serious concerns. These are all problems that can happen when doing business outside of America. When language barriers exist, it is difficult for everyone to understand the solutions for these problems.

Additional Helpful Information  

Click below of helpful information about Wire Harness Assemblies:

Finally, for more information on Ground Straps, please click these helpful links: 

onshoring custom manufacturing


Falconer Electronics Inc. is seeing a strong upward trend in onshoring custom manufacturing. As a United States based contract manufacturer for over 30 years, we have witnessed many ups and downs in manufacturing.

Recently, it seems like more and more conversations revolve around bringing manufacturing back to the States. One particular reason is due to poor quality products produced in foreign countries. 

Outsourcing production to a manufacturer lends tremendous benefits. Especially for a small business or a start up. However, there are numerous challenges and threats to outsourcing manufacturing operations. Therefore, these threats increase dramatically when you outsource to foreign countries. In addition, outsourcing abroad brings many hidden costs.

These determining factors include the heavy cost of monitoring operations as well as quality control. There is also a lack of intellectual property protection as well as extending the supply chain.

Consequently, these are all reasons a company benefits when onshoring custom manufacturing their products instead of offshoring.

Check out these excellent articles:

“Small Businesses Find Overseas Factories Lead to Colossal Headaches”

“The American Onshoring Trend Is Gaining Momentum”

Benefits of Onshoring Custom Manufacturing

This positive trend with manufacturing operations returning to the U.S. holds great promise. Especially for small U.S. manufacturers. The outsourcing of production abroad to foreign countries certainly carries a negative impact on the U.S.

Therefore, terms such as onshoring, reshoring, and redesign manufacturing are generating a new buzz. Onshoring drastically improves lead times. It also cuts inventory levels. For example, at Falconer Electronics Inc., being located close to vendors narrows the supply chain.

Like Falconer Electronics, other companies in the U.S. are also realizing the many benefits to manufacturing products Stateside. However, this is after decades of losing U.S. manufacturing jobs. The majority of which went to lower cost countries such as China.

Consequently, wage gaps are shrinking between China and the United States which delivers another onshoring benefit.

In addition, the U.S. offers superior infrastructure, automation, education, information technology, and transportation. This may be arguable, but since we are biased, we certainly think we hold an edge. 

Risks with Intellectual and Proprietary Information  

Onshoring custom manufacturing  while partnering with the right company dedicated to your success delivers powerful results. 

The positive impact improves everything from strategy, supply chain, staffing, and operations.

Control over the protection of intellectual property is another one of the many benefits. Especially since there is a huge vulnerability when relying on foreign suppliers. Meanwhile, the threat of stolen proprietary information and processes decreases dramatically in the U.S. 

The loss of proprietary information to a foreign supplier brings devastation to a company. Most noteworthy, legal recourse and recovery is challenging at best. As a result, a company has more control when they choose onshoring compared to offshoring.

Quality Control in Onshoring Custom Manufacturing

Quality control is another serious issue. Separating product development and manufacturing operations can be extremely detrimental. If prototyping and product development are conducted in the States while production heads overseas, quality and consistency may suffer greatly.

Managerial focus, when operations are halfway around the world, lends  a significant disadvantage. Partnering with experts who possess vast experience places you in a position of strength. Close proximity to vendors allows site visits which in turn consistent quality inspection.

Meeting with vendors and suppliers face-to-face creates the opportunity to build long-term trusting relationships. The opportunity to see your products in production while also meeting the actual individuals producing your product delivers incredible value. 

Wrapping It Up

Thanks for stopping by to check out this post. We deeply appreciate it.

 To learn more about Falconer Electronics, check out these helpful links on Ground Straps: 

Lastly, to learn more about Wire Harness Manufacturing, check out these helpful links: 

Offshoring occurs when a company chooses to have their production outsourced to a country outside the United States.

This is due to the hope that their labor costs will be lower.

However, there’s something these companies don’t realize.

Their actions will have a negative effect on the country as a whole.


Offshoring Effects the Economy

There is an effect on the economy when production moves out of the United States.

However, it is not noticeable right away.

This is due to the manner in which a company outsources their business.

In some cases, a company does this in stages.

However, when a company begins to offshore, even just a single production line, it can affect the local economy by: 

  • Decreasing Jobs 
  • Reducing Consumer Spending
  • Negatively Impacting Local Business 

Decreasing Jobs

When companies all over the U.S. begin moving their businesses offshore, there are consequences.

Consequences such as:

  • A decrease in American jobs in favor of an overseas workforce that is cheaper.
  • Additionally, companies terminating some or all of the positions in America.
  • An increase to the unemployment rates for the U.S.
  • Furthermore, a decrease in the amount of monetary flow which will eventually affect the entire country.

Production Effects Consumer Spending 

Offshoring production heightens the economy in other countries. Meanwhile, the economy in our own country will decrease.

This is due to employees spending less caused by reduced income. 

Therefore, those funds are no longer circulating throughout the U.S.

However, this lack of circulated money doesn’t just affect the larger companies.

It makes it more difficult for small and local businesses to thrive as well.

Furthermore, individuals are less likely to spend their money on U.S. based products.

Especially, if there is less money to go around.

Eventually, money goes toward products that are lower in quality from cheap labor countries.

Furthermore, this will increase unemployment.  

Offshoring and It’s Impact on Local Businesses

Offshoring does not just affect larger businesses who move out.

When companies and jobs leave a community, it also negatively affects the businesses that are still here.

Fewer jobs lowers consumer spending. 

The flow of money connects all businesses.

The American economy is dependent on keeping businesses here as well as their employees.

Every lost manufacturing job impacts local service providers, retailers and restaurants. 

In conclusion, the entire country suffers when companies move to other countries.  

Wrapping Up

For additional information on Wire Harness Manufacturing, please check out these helpful links below: 

Finally, for more information on Ground Straps, please click these helpful links: 



Safety for Outlet Strips

Safety            Outlet strips have many different uses in everyday life. They have many safety features as well. These features keep everyone safe. Extension cord, power strip or surge protector devices provide temporary power to electrical devices. Especially those that need to be used in areas not located near a wall outlet. Therefore, these are a temporary fix. They shouldn’t be in use for more than 90 days in a single spot.

Most light duty extension cords have a rating for a maximum of 10 amps or 1200 watts. Whereas most strip cord, power strip, and surge protectors have a 15 amps (1875 watts) rating. All Outlet strips contain surge protectors. A surge protector is a device who’s purpose is to protect electrical devices. This protection is from voltage spikes. Also a surge protector attempts to limit the voltage supplied to an electric device. This is done by either blocking or shorting to ground any unwanted voltages above a safe limit. In conclusion, all outlet strips also include an on/off switch and are made to be as safe as possible.

15 Important Safety TipsSafety

  1. The total watts should not exceed the rated capacity of the extension cord. This is also true for power strips as well as power tap or surge protectors.
  2. Power cords are designed for computers as well as audio and video equipment. They are also for use with musical instruments and home movie lighting. They are also designed for home workshops and laboratory equipment.
  3. Ensure that you purchase power strips with an internal circuit breaker.
  4. Use power strips sparingly.
  5. Look for Outlet strips that are UL or ETL Certified.
  6. Do not knot or twist the cord.
  7. High voltage items can cause an overload to outlet strips. Objects such as refrigerators, microwaves or space heaters. 
  8. Do not locate a surge protector in a moist or wet environment.
  9. Also, don’t locate a power strip in any area where carpet, furniture, or any other item will cover it. These items will limit or prevent air circulation.
  10. Never use a cord that feels hot.
  11. Additionally, do not use a cord that is showing signs of damage in any way.
  12. Never nail, staple, or tape power cords. This includes to desks, walls, ceilings, or another object.
  13. Furthermore, use exterior rated cords for outside use.
  14. Also do not use indoor extension cords outdoors.
  15. Do not extend extension cords by plugging into another. Overloading can occur when multiple devices are plugged into one cord.

Wrapping Up

Want to learn more about ETL and UL? Check out these blogs:

For additional information on Wire Harness Manufacturing, please check out these helpful links below: 

Finally, for more information on Ground Straps, please click these helpful links: 

Crimping wires is a core function for all Wire Harness ManufacturersConsequently, at Falconer Electronics we like to say that crimping wires with strict accuracy and precision is an art form. 

Developing a highly skilled staff takes years. It requires a keen eye along with a steady presence and laser focus when crimping wires. 

As terminals and connectors continue to decrease in size, crimping wires with precision demands skill, dedication and stamina. 

Our team works closely with each customer to ensure that all crimped wires comply with industry standards and customer requirements.

Many factors contribute to crimping wires that meet rigorous industry standards.

Customers provide the necessary drawings and instructions with specific details for sizes, crimp height and pull strength.

Additionally, wire insulation and connector compatibility also both serve as critical functions for successfully crimping wires.

Above all, our goal is to ensure product integrity with electrical requirements on each and every wire harness assembly.

Crimping Wires to IPC Standards 

Crimping Wires at Falconer Electronics

Crimping Wires at Falconer Electronics

With over 30 years of experience in cable and wire harness assembly, crimping wires is a daily activity that our team takes tremendous pride in performing meticulously.

In a previous Wire Harness blog post, we discussed IPC Wire Harness Assembly standards.

The IPC/WHMA-A-620C serves as the only industry-consensus international Wire Harness Assembly Standard for the performance and acceptance of cable and wire harness assemblies. 

As an IPC certified Wire Harness Manufacturer, Falconer Electronics strictly follows the IPC/WHMA-A-620: Requirements and Acceptance for Cable and Wire Harness Assemblies.

To learn more, click on these links below: 

IPC = Association Connecting Electronics Industries:

WHMA = Wire Harness Manufacturing Association:

Crimping Wires Do’s & Don’ts

The IPC/WHMA-A-620 standard provides the necessary guidance on crimping wires that are acceptable vs defective.

Here are a few examples of Wire Harness Assembly Do’s and Don’ts: 

Crimping Wire Do’s:

  • Insulation crimp tabs fully wrap as well as support insulation
  • Insulation fully enters and extends past the insulation crimp tabs
  • Prepared wires must also be in solid working condition – cannot be scraped, nicked, severed or damaged
  • Wires retained in the connector
  • Crimp indent is centered
  • Insulation crimp must also provide a minimum side report of 180 degrees 

Crimping Wire Don’ts:

  • Wires should not be flattened, untwisted, buckled, kinked or otherwise deformed.  
  • Insulation should show no signs of pinching, pulling, fraying, discoloration, charring as well as burning.
  • The insulation crimp also needs to fully support and wrap insulation without causing any damage or breaking the insulation.
  • Broken insulation can expose wires causing safety issues as well as potential hazards.
  • No cuts or breaks in the insulation
  • Insulation also cannot be charred
  • Insulation melted into the wire strands
  • Wire not secured by crimp
  • Contact has visible cracks and fractures
  • No Birdcaging – in other words, no wire separation

However, these are just a handful of the requirements.  

To learn more about the Wire Harness Manufacturer’s Association and A-620 Standards, please click here:

Reference: IPC/WHMA – Requirements and Acceptance for Cable and Wire Harness Assemblies

Wrapping It Up 

Lastly, to learn more about Wire Harness Manufacturing, check out these helpful links: 

In addition, check out these helpful links on Ground Straps: 

Falconer Electronics has served as a Custom Wire Harness Assembly Manufacturer since 1985. Producing high quality wire harness assemblies takes a tremendous amount of time, skill and expertise.

However, many companies do not possess the experience, skilled staff or proper equipment to manufacture wire harness assemblies internally. Therefore, when selecting a custom wire harness manufacturer to partner with, it is crucial to team up with a company that you can trust. In addition, delivery times, quality, reliability and quick turnaround play key factors with your decision as well.

Custom Wire Harness Assembly

Crimping Wires at Falconer Electronics

There are many functions of a custom wire harness assembly that continues to be primarily manufactured by hand. Due to the challenging task of assembling cables and wires, it is difficult to fully automate the process. This is particularly common when dealing with high mix and low volume projects. 

All sorts of enjoyable activities go on at a Wire Harness Manufacturer. For example, Wire Harness Manufacturers handle a wide variety of custom wire harness assembly services including:

  • Cutting individual wires
  • Crimping individual wires
  • Twisting wires
  • Soldering wires
  • Applying heat shrink
  • Crimping terminals
  • Sleeving individual wires 
  • Assembling wires into housing and connectors
  • Plus much more

The Custom Wire Harness Assembly process is typically not economical to outsource overseas to foreign competitors. Especially since many companies rely on short lead times and quick turnaround. Low volume wire harness assemblies are difficult to predict demand.

Teaming up with a custom manufacturer in the U.S provides the necessary flexibility to receive product on time while not overstocking. Turning over inventory quickly while maintaining low inventory levels drastically helps improve your profitability. In addition, speed and agility lends a tremendous competitive advantage to your company. 

Quality Control with Custom Wire Harness Assembly

Producing high quality wire harnesses is a core competency and strength at Falconer Electronics as we enter our fourth decade.  Testing and Quality Control of every product is an absolute top priority. Customers consistently rank our services at near perfect levels. Our company commitment is driven by producing the highest quality of product every time. 

Companies have trusted the team at Falconer Electronics throughout many industries such as auto, rail, military products, health care, industrial work lights and much more. 

Please contact our customer service team with any questions. 

Wrapping It Up

Lastly, to learn more about Wire Harness Manufacturing, check out these helpful links: 

In addition, check out these helpful links on Ground Straps: 



As we continue our blog series on New Product Development, this post covers creating a proprietary product line. In particular, creating a proprietary product line from the perspective of a custom manufacturer.

Our team at Falconer Electronics takes deep pride in helping our clients to create, produce and deliver new products. We work closely and relentlessly with our clients to manufacture products as close to perfect as possible.

The prototype and test phase are both so critical to strive for perfection during early stages when developing a new product. Critical factors include quality and safety as well as producing your product at a competitive price.

Many custom manufacturers make products for other companies but do not possess a proprietary product line themselves. Typically it is not a priority. Custom manufacturers are just too busy serving existing customers.

Over time, a small custom manufacturer develops the skills and expertise at a proprietary process. Yet, they lack either engineering or a product design team to develop a proprietary product line of their own.

Another challenge faced includes not only developing the product but also possessing the ability to aggressively market the product as well. Creating a steady sales channel makes or breaks a product. The greatest product without revenue is simply nothing more than well-kept secret.

Proprietary Product Line at Falconer Electronics 

Well, we found it necessary to not just talk the talk with developing a new product for our customers. We also have to walk the walk. So we created our own proprietary product line.

Falconer Electronics offers a variety of proprietary products.

The list includes:

Creating our own proprietary line of products delivers tremendous benefits to our customers. Especially when working with clients developing their own proprietary product line.

For example, we use our own Wire Harness Assemblies and Printed Circuit Boards in our products.

This simply strengthens our company on many levels. This creates deeper experience with our staff, increases buying power with our vendors and helps maximize capacity with our equipment and machinery.

Since launching our e-commerce store with our proprietary product line, we have engaged with new customers in exciting industries that were completely new to us.

Let’s take a look at the proprietary product line that we developed over the years.

 Ground Straps 

Our team produces thousands upon thousands of high quality Braided Ground Straps for OEM’s.  Way too many to count since our humble beginnings in 1985. In hindsight, we should have kept track similar to McDonald’s tracking the number of burgers served.

Anyway, we decided to convert this proprietary process into a proprietary product line of ground straps.

To broaden the line, we also offer the opportunity to create an Instant Ground Strap for customers looking for a custom size. We call it the Ground Strap Express (CLICK HERE). This allows a customer to build a Ground Strap to the exact dimensions necessary to complete a project.

Commercial Power Strips 

Our proprietary product line of commercial power strips developed out of a need for one of our largest customers. Lowe’s approached Falconer Electronics two years ago to manufacturer a Heavy Duty Industrial Power Strip for artificial Christmas tree displays. The project required a tight deadline along with safety certification from ETL.

The project was such a success for our company that we now offer these Commercial Power Strips on our e-commerce store. Since launching this new proprietary line of power strips in January, we have engaged with numerous new customers in completely new markets for our company.Proprietary Product Line

Magnetic Work Lights

We would also like to introduce you to our exciting lineup of Magnetic Work Lights. You can now purchase Magnetic Based Work Lights manufacturer direct as well as Industrial Magnets on our brand new e-commerce store.

Magnetic Trouble Lights 

Heavy Duty Magnetic Trouble Lights produced at Falconer Electronics offer a sturdy magnetic base. Therefore, allowing you to work hands-free. Tackling challenging projects is easier due to the lights flexibility and reliability. Also, these lights are equipped with Falconer Electronics’s “Swing-open” Guard that permits immediate bulb replacement. Each Magnetic Trouble Light is assembled in the U.S. with components that are purchased domestically and globally.

Click here to view our selection of Magnetic Trouble Lights

Magnetic Spotlights

Durable Magnetic Spotlights produced at Falconer Electronics offer a sturdy magnetic base allowing you to work hands-free. Also, lights provide the flexibility and reliability to tackle challenging projects. Maximum reflection occurs due to the aluminum reflector. Therefore, providing ideal lighting wherever maximum illumination is required.

Furthermore, each magnetic spotlight is assembled in the U.S. with components that are purchased domestically and globally. They are perfect for industrial and warehouse settings as well as projects around your office or home.

Click here to view our selection of Magnetic Spotlights

LED Flashing Lights 

We produce the circuit board inside these LED Flashing Lights. Also, the sturdy plastic base is produced right around the corner from us at a local plastic fabrication company. Therefore, we exhaust every effort to Buy American first.

Click here to check out our Magnetic LED Flashing Lights

Wrapping It Up 

Thanks for reading our post. Check out the excellent article building a proprietary product line from – “How To: Grow a Product-Based Business“.

For additional information on manufacturing tips, please click on these links below:

Lastly, please connect with us on FacebookTwitterGoogle+, and LinkedIn.


Welcome to the Ground Strap QuoteBuilder

Looking for a Custom Ground Strap?

In particular, a ground strap manufactured in the U.S.A.

Well, look no further. You have landed at the right place.

Falconer Electronics proudly announces the brand new Instant Ground Strap QuoteBuilder: CLICK HERE

What is the Instant Ground Strap QuoteBuilder?

Creating a custom ground strap and receiving a quote immediately just became a whole lot easier with the Instant Ground Strap QuoteBuilder.

The process is not only Fast & Easy but also FREE!

In addition, it takes less than 60 seconds to complete.

Our goal is to make your job simple. You have things to do, people to see, and many other tasks that need your attention.

The Ground Strap QuoteBuilder allows you to create a Custom Ground Strap in 5 quick steps.

Once finished, The Ground Strap QuoteBuilder delivers a quote of your custom made ground strap to your email literally within seconds.

No Waiting for a Response for Your RFQ

Tired of submitting RFQ’s only to wait for days upon days for a response?

Struggling to find a reliable vendor and waiting for pricing should NOT be on your task list today.

Is that efficient? No. Effective? No. A colossal waste of your time? Yes!

Not only can you save time with the Ground Strap QuoteBuilder, you can also check out our line of Stock Ground Straps for immediate purchase.

Enjoy Tremendous Savings 

With the Ground Strap QuoteBuilder, you also have the peace of mind purchasing DIRECT from the manufacturer.

No Middleman. No additional retail markups. Only Low Prices!

Made In The USA

All Ground Straps at Falconer Electronics are Made in the USA right here at our facility.


Let’s Get Started


STEP 1: RoHS Compliant 

RoHS Compliant = Lead or Lead Free

Simply click YES or NO

Ground Strap

STEP 2: Select Width and Length 

Select the width of the braided wire for your project.

Select from either 1/4″ and 1/2″.

Enter the Length.

Click “NEXT”

Ground Straps

STEP 3: A & B Side Terminal Selection 

Next – Let’s select your terminal for side A.

We offer 5 sizes:

  • #8 Stud Ring
  • 1/4″ Stud Ring
  • 3/8″ Stud Ring
  • 1/2″ Stud Ring
  • 5/8″ Stud Ring

Select your terminal for side B.

  • #8 Stud Ring
  • 1/4″ Stud Ring
  • 3/8″ Stud Ring
  • 1/2″ Stud Ring
  • 5/8″ Stud Ring

Click “NEXT”

Ground Strap Express

STEP 4: Terminal Orientation 

Select the Terminal Orientation  from 7 Choices.

Click “NEXT”

Ground Straps

STEP 5: Quantity 

Enter your Quantity

Click “NEXT”

Ground Strap Express


Need another quote? Click “YES”

You have the option to continue on and add additional quotes.

All done and ready to receive your quote? Simply click NO.

Provide your name, company name, phone number & email  & Click Submit

Viola! Your quote is in your email.


Convert Your Ground Strap Quote to an Immediate Order 

Ready to place your order?

Once your quote is received and you fall in love with the price – you can make an immediate purchase on our ecommerce shopping cart.

Go right ahead. Select “Add to Cart”


Let’s Get Social

Thank you for reading this post on the Ground Strap QuoteBuilder.

In addition, to learn more about outsourcing your Wire Harness Assemblies, please click on the links below:

Lastly, we love connecting with customers. Please connect with us on Twitter and LinkedIn.




8 Outlet Commercial Power Strip

Developing a new product brings a wide range of emotions such as excitement, frustration, encouragement, depression, and exhilaration (not necessarily in that order).

The bottom line: Developing a new product brings hope. Hope that the product works and works extremely well. In addition, the hope that customers welcome this new concept. Most importantly, the hope that customers will eagerly part with their hard earned money and purchase your new creation.

Profits = Sustainability

Profits bring sustainability for your new product as well as your company. Yet, before profits flow in, you need to make sure you produce a quality product. Furthermore, a quality product that (at the very least) meets and preferably exceeds customer expectations.

Proof of concept is critical. However, saying something works versus actually demonstrating that your product works, delivers an entirely new level of credibility.

Here is an interesting video from Steve Jobs on product development:

New Product Development and Prototypes at Falconer Electronics 

Having a number of proprietary products ourselves, we also fully understand the challenges faced with new product development as well as creating a functioning prototype.

For example, our proprietary product line includes Magnetic Work Lights, Commercial Power Strips and LED Flashing Lights.

We also produce numerous prototypes for clients by building Wire Harness Assemblies, Ground Straps and Printed Circuit Boards.

10 Steps for New Product Development

Below includes a list of steps when developing your next new product:

  1. Idea
  2. Create Concept
  3. Drawing & Schematics
  4. Product Requirements
  5. Create Prototype
  6. Test
  7. Revise & Enhance
  8. Product Production
  9. Product Launch
  10. The final and most important step: Sell TONS of your new product. Then you and your family go out and celebrate. See how easy that was! (See our blog series on marketing new products).
Additional Resources To Help With Your New Product Development 

new product

Check out these outstanding articles on developing new products and creating prototypes:

Let’s Connect

Thank you for reading our blog on new product development.

Also check out these helpful blog posts:

Lastly, please connect with us on FacebookTwitterGoogle+, and LinkedIn.









Are you deeply passionate about electronics? Do you love history as well? If so, you need to check out the Thomas A. Edison Papers at Rutgers University (click here).

The Edison Papers at Rutgers University serves as an extremely ambitious project dedicated to the man credited with 1093 patents during his lifetime from 1847 to 1931.

Thomas Edison changed history with his relentless drive to make the world a better place with his amazing inventions and new product development.

However, Thomas Edison played many roles in his illustrious life. The list includes not only inventor and entrepreneur but also a loving husband and father. Above all, Thomas Edison represents massive success.

Furthermore, the incredible legacy of Thomas Edison continues on today with great thanks to the dynamic team at Rutgers University.Edison Papers

Rutgers University Professor Thomas Jeffrey, Senior Editor Emeritus Edison Papers 

This post continues our blog series on the Thomas and Mina Edison family. Hence, during our research on Thomas Edison, we discovered a local connection with the Edison family and Chautauqua Institution.

First, we began our research by contacting Chautauqua Institution. Chautauqua Institution Archivist Jonathan Schmitz then connected our team with Dr. Thomas Jeffrey, Professor at Rutgers University and Senior Editor Emeritus of the Edison Papers.

Consequently, Dr. Thomas Jeffrey recently blessed our company with the opportunity to interview him in person. Click here to hear sections of that interview

In addition, our conversation with both Jonathan Schmitz and Dr. Thomas Jeffrey led to a deep interest to continue exploring the Edison Papers.

As a result, it was exciting to see all of the pieces on the Edison Papers website from the Oliver Archives Center at Chautauqua Institution. Especially since Jonathan Schmitz allowed us to go through many of the same documents.

Click the link below to learn how the Edison Papers team made the Edison-Miller connection to Chautauqua Institution:

Miller Family Papers to add Chautauqua chapter to Edison project

Creating The Edison Effect Through Course Development

Below includes a video with Dr. Paul Israel, Director and also General Editor of the Edison Papers:

Below includes a link to another video with an interview with Dr. Paul Israel on PBS:

The Mission of the Edison Papers Project

Due to the deep dedication and commitment from the team at Rutgers University, their website is loaded with a wealth of information. In particular check out the  Digital Edition of the Edison Papers.

Therefore, it certainly seems like any piece of information imaginable regarding Thomas Edison resides on the Edison Papers website.

For example, according to the Rutgers University website the mission of the project states:

One of the most challenging, versatile, and collaborative projects ever anchored by humanities scholarship, the Thomas A. Edison Papers is a unique resource for understanding the unbounded themes, variations, and processes of invention and innovation because it combines the major research capabilities of Rutgers University with a team of diversely interested specialists.

A major goal of the Edison Papers is to produce a selective fifteen-volume book edition of transcribed and annotated documents. The book volumes provide not only an overview of Edison’s life and career but also significant resources for understanding the development of electrical and other technology, as well as the emergence of new technology industries.

The Edison Papers was established under a Board of Oversight which consists of Rutgers, the State University of New Jerseythe National Park Servicethe New Jersey Historical Commission, and the Smithsonian Institution.

Finally, let’s take a tour of the Edison Papers and explore the tremendous amount of information the team at Rutgers organized:

Edison Personal Artifacts 

The Edison Papers offers literally thousands of documents organized by the categories below:

Thomas Edison Business Related Documents 

Additionally, you can browse through thousands of documents on Thomas Edison’s business dealings:

Thomas Edison Inventions 

Above all, for aspiring inventors, you can also browse by inventions of Thomas Edison:

In conclusion, if you are looking for a blueprint on building game changing inventions and seeking entrepreneurial success, dedicate some time browsing the Edison Papers. You will learn tons.

Most importantly, please take a moment to thank the team at Rutgers University for all of the hard work over the years. Job well done Scarlet Knights!

Let’s Connect

Falconer Electronics serves as a U.S. manufacturer of Commercial Power Strips, Ground Straps and also  Wire Harnesses dating back to 1985.

Also, click on these links to learn more about our Wire Harness Estimator and our new Ground Strap Express!

Lastly, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Many small manufacturers in the U.S. struggle to determine if the product that they assemble, manufacture or produce truly qualifies for the labels “Made in USA” or “American Made”.

Made in USA, American Made

Complying with American Made Standards

The world is shrinking fast. Competition is fierce. In addition, the internet has escalated a true global economy. Every country fights rigorously for consumers to purchase their products.

Consumers commonly make buying decisions based on labels. An important label includes country of origin. For example, U.S. manufacturers proudly label their products with “American Made” or “Made in the USA”. “American Made” represents quality products and lends a strong selling point for the product.

Unfortunately, there is confusion behind the definition of “American Made”. As a result, manufacturers in the U.S. are eager to comply with the “American Made” or “Made in USA” standards. Especially, as long as the standard is consistent and well defined.

Yet, some companies are too eager to capitalize on the “American Made” logo that actually do not qualify. Therefore, an “American Made” standard helps prevent those companies from just throwing a sticker on any product. Specifically, those that do so while disregarding its true origin.

What Does “All or Virtually All” Mean?

A Google search for “Complying with Made in the USA” produces 854,000 results. Furthermore, the #1 ranking is a link to the Federal Trade Commission website. The article is titled: Complying with the Made in USA Standard. The page offers a link to a pdf that dates back to 1998. However, it is still relevant today. This pdf states:

Traditionally, the Commission has required that a product advertised as Made in USA be “all or virtually all” made in the U.S.

“All or virtually all” means that all significant parts and processing that go into the product must be of U.S origin. That is, the product should contain no — or at least negligible — foreign content.-Federal Trade Commission pdf

So what does “or at least negligible” actually mean?

Manufacturers may think that they are truly making American products with all domestic suppliers. However, certain parts or raw material may be imports from a foreign country. All unbeknownst to the manufacturer.

Even if you purchase raw materials, parts, and components from a domestic distributor, those products may have originated in another country.

Manufacturers have to be aware of all aspects of their products. However, this can be a difficult undertaking. When you purchase components from a vendor they will not always provide you with the origin of those pieces. This is especially true if there is a larger component that has hardware or other parts that form the component as a whole. This is the situation that California manufacturer Maglite found themselves in.

Manufacturer Responsibility

As an example, Maglite, a California lighting manufacturer made national news. They lost a lawsuit over false “Made in USA” claims. Maglite is committed to American manufacturing and an amazing American entrepreneurial success story (click for video from ABC News). However, the lawsuit boiled down to a microchip and a rubber seal. Both of which had origins overseas. Therefore, costing the owner thousands of dollars in legal defense. Meanwhile, they still lost their case.

Check out this clip from CNBC (click here).

Unfortunately, in this case, the responsibility fell on the manufacturer. Like many manufacturers, they felt they were playing by the rules but fell short according to the court of California. Also, ignorance is not a reliable excuse or defense. There are companies that find themselves in trouble even when intentions are honest and genuine.

The Best Intentions

Manufacturers may have the best intentions of purchasing domestic goods. However, these products are not always available. Specific countries, geographical regions, climates, and many other factors affect the production of certain products in those areas. You may have a product that you assemble in the U.S. Production of that same product could occur with raw components originating from various countries.

In many cases, it is just not cost-effective to produce certain products in the U.S. Basic economics says that supply and demand control a market. Price is typically a key ingredient. What if the production of a product isn’t at a price that a customer is willing to pay? It is going to be extremely challenging to create a product that will sell. It will also be hard to sustain a profitable company due to the lack of interest in your product. Well at this point you are thinking, thank you Captain Obvious.

How Can You Protect Your Business?

One of the main ways to protect your business from lawsuits like that Maglite experienced is to be aware of your sourced parts. Also, before claiming your product is “Made in America” be aware of the laws in your state.

Why would the state you’re in make a difference? Different states have different definitions of “American Made”. Unfortunately for Maglite, California has one of the strictest definitions in the country (click here). Other states, however, acknowledge that there needs to be some leeway when it comes to hardware.

In Maglite’s case the components they got in trouble for were not available in the United States at the time. Maglite had done searches for that product and came up empty handed. That is another issue that manufacturers need to be aware of. When a component is not available in the U.S. what do you do? Also, how can you still receive the “Made in America” Stamp?

What if You Can’t Find Your Components in The U.S.?

Unfortunately, there are not many options. Depending on the component you may be able to employ a local business to manufacture the part for you. If your business is lucky enough to have ties to another manufacturer that would be willing to help, you are then all set. There is also the possibility of you manufacturing the piece yourself. The plus side to this is you would know exactly where the piece came from.

However, what if this isn’t an option? This is a very real possibility. There may not be an option of creating your own part. Whether due to time constraints or available resources. In this situation, you will need to find another way.

What if the only option is to import that specific part like Maglite had to? This is when you need to be aware of your state’s specific laws on the matter. If you are lucky enough to be in a state that has wiggle room depending on the component you may be able to import what you need without penalty.

However, if you are in a state with strict laws (like Maglite) you may have no choice then leaving off the “Made in America” label.

According to an article in the Daily Bulletin, Maglite hopes for a federal bill on the “Made in America” standard. A federal bill would certainly level the playing field as well as clarify the definition.

How Do You Still Represent Your American Workforce?

Do not lose all hope in that situation! There are other labels that you can use that will still encourage customers to buy your product. Some of these labels include:

  • “Assembled in America”
  • “Contains –% American Product”
  • “Final Product Assembled in the USA”
  •  also “USA Factory Assembled”

Each of these labels still encourage loyal customers and patriotic sales. Customers will see one of these labels and know that they are purchasing a product from an American Factory. Furthermore, with these labels and others like them, you can represent your American workforce and still be in compliance with the law.

Connect with Us

To learn more about Falconer Electronics, you can check out information on our American Made Ground Straps and Wire Harnesses.

Also, click on these links to learn more about our Wire Harness Estimator and our new Ground Strap Express!

Lastly, please connect with us on FacebookTwitterGoogle+, and LinkedIn.



Businesses plunging into ecommerce in the 1990’s certainly faced many challenges. One of the greatest challenges? Finding new customers. Think about this for a moment……….Google did not exist back then. Let alone Google AdWords to help with your search marketing efforts.


That’s right! No Google. Well, not as we know it today anway. Larry Page and Sergey Brin founded the idea and concept for Google in 1995. Click here for a cool article on the founders from Wired magazine. An amazing American Entrepreneurial success. Massive success! It is hard to imagine going an entire day without using Google.

Google AdWords

We frequently assist small business owners with New Product Development. In particular with Ground Straps and Wire Harness Assemblies. However, developing the product is only half the battle. Marketing your product and business aggressively is critical. Entrepreneurs and small business owners must take full advantage of every resource possible.  Especially in these competitive times. This post continues our blog series on B2B Marketing.

Google AdWords

Can you imagine life now without Google? Nearly unfathomable. Try telling a high school or college student to do research without access to Google. Heavy odds they would be lost.

To take it one step further, try telling an ecommerce company today that they cannot use AdWords. They would not have pleasant words for you (major understatement).

Well, that was ecommerce in the 1990’s. Google changed the world and is now a verb (“Google it”). An essential function that millions of companies rely on daily.

AdWords allows potential customers to find your website quickly and easily.

When you conduct a search, the top words with an “AD” button next to the URL (or company website) designate an  AdWords listing.

Google AdWords runs as an auction. It does not cost a company a single penny to be listed in that position. You only bid to be there. A charge only occurs once an individual clicks on your ad. This is called “Pay-Per-Click” or PPC. You only pay when someone clicks on your ad.

Resources for AdWords 

Confused? No problem. Plenty of outstanding resources exist that provide valuable information on how to execute PPC strategies.

Check out these several excellent websites below for additional help to tackle PPC:

Let’s Connect

Thank you for reading out post. This continues our blog series on B2BMarketing.

Also, to learn more about Falconer Electronics, please click here.

Lastly, let’s get social! We would love to connect with you on FacebookTwitter, Google+, and LinkedIn.


Everyone knows that summertime means outdoor activities. Also, it means trying to stay cool indoors. Summertime Gadgets are a must to get through the hot days and nights. Below we have compiled a list of electronic gadgets that are must haves for summer survival.

Summertime Gadgets

Indoor Summertime Gadgets

During the summer there are days that take all your energy away. The heat is too hot. The sun is too bright. Also, the air outside is too sticky. Luckily there are electronic devices that can help you enjoy your home during those unbearable summer days.

  • Fans: This may seem like a very basic Summertime Gadget. However, fans are very useful during hot weather. Without Air Conditioning fans are the difference between feeling like you are melting and feeling like you are still human.
  • Air Conditioning: Not everyone has an Air Conditioner. For those of us without we are very grateful for public places that pipe in cool air. It has been a long-time tradition to go to the movies in the Summer to suck up that “free A.C.”. Also, with the enticing smell of that theater popcorn, there is the added intrigue of the big screens.
  • Streaming Sticks: Summer is notorious for repeats on television. However, with a streaming stick like the Amazon Fire StickGoogle Chromecast, or Roku, you can get more apps with more options. These streaming sticks are the perfect gadget for those days where the outdoors are not your friend.
  • Ice Cream/ Snow Cone Maker: There is no better way to beat the summer heat then by enjoying a nice cold treat. Even better is when you can make them at home! With Summertime Gadgets like an ice cream or snow cone maker, you can create your own flavor combinations and always have an ice-cold treat available.

Versatile Summertime Gadgets

There are some gadgets that are not strictly indoor or outdoor. These are the gadgets that are easy to slip into a beach bag or pocket and take on the go. Furthermore, they are also convenient to have indoors to break up those hot days that you don’t want to leave the comfort of home.

  • E-Readers/ Tablets: Electronic readers are perfect for traveling in the summer. Instead of having to choose a few books that will take up room in your luggage you can download hundreds of books to fill your summer reading lists. These tablets and e-readers are compact enough to slip into luggage or a beach bag. They are also perfect for just lounging in a cool room of the house. Many e-readers or tablets have their own Wi-Fi. With this technology, you can continue communication with friends and family, even when you are enjoying the sun and water or when you want to chat to break up a quiet day at home.
  • Bluetooth Speakers: Whether at an outdoor cookout or doing chores inside the house Bluetooth speakers can change the mood of any day. Everyone has their favorite songs and what better way to enjoy them then to play them out loud.
  • Handheld Misting Fans: Misting Fans are convenient for summer trips to theme parks or just for those too hot days at home. They are small enough to travel with you anywhere. Also, they are battery powered so they won’t spike up your electric bill.

Outdoor Summertime Gadgets

There are days where the best place to be in the summer is outside. You can enjoy the fresh air while spending time with family and friends. There are electronics that can enhance these times.

  • Outdoor Theater Systems: It is becoming more popular for families to set up Summertime Gadgets that create outdoor theaters. Summertime is perfect for movie watching outside due to the warm weather. Also, there is no concern of the kids oversleeping their alarms for school the next morning, because there is no school.
  • Waterproof Speakers: Summer days are for the pool. Often families with pools do not keep them to themselves. Therefore, there is a need for further entertainment while enjoying the cool water. Speakers that can be near the pool can make a get together more festive. Everyone loves a soundtrack for their summer parties.
  • Electric Thermometer: It is difficult to plan any outdoor activities during summer. You need to be aware of the weather. An electric thermometer can help. With the new technologies available you can keep up with the local weather. Not only do these thermometers tell you the temperature outside and inside. Also, there are certain types that can tell you what weather is coming later in the day or even throughout the week.
  • Waterproof Digital Camera: Everyone has moments they wish they had been able to capture in a picture. With a waterproof camera, you won’t miss any moments on land or in the water. Also, many manufacturers are making kid-friendly cameras. Even the kids can record memories of their favorite outings.

Contact Us

Check out more of our blogs here

Have your own Summertime Gadgets that you are working on? Check out our Wire Harness Page and our Ground Strap Page!

Are you in the market for some new gadgets? Check out our Product Page where you can find lighting, outlet strips, and ground straps!

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On this day, 153 years ago, July 6, 1865, an amazing woman was born: Mina Miller Edison. Mina was a positive force which she demonstrated with her many incredible achievements. Especially as the wife of Thomas Edison, a wonderful mother and her involvement in numerous community projects.

Mina Miller Edison

Mina Miller Edison & Chautauqua Institution

Our team excitedly decided to create a blog series on Thomas Edison. Being an electronics manufacturer (Wire Harness Manufacturing and Ground Straps) for over 30 years plus being history buffs, a blog series on Thomas Edison sounded educational and fun. 

While conducting research on Thomas Edison, we discovered that Thomas Edison and his wife Mina Miller Edison also share deep roots in our local community, Chautauqua County.

Mina was not only the wife of Thomas Edison she is also the daughter of Lewis Miller. Mina’s father Lewis Miller was a hugely successful inventor and industrialist as well as the founder of Chautauqua Institution.

Mina Miller and her family spent their summers at Chautauqua Institution (check out our blog from earlier this week to learn about Chautauqua Institution). Mina’s father was one of the founders in 1874. Therefore Mina was extremely proud of her father. Especially his legacy in founding the historic Chautauqua Institution.

Furthermore, Mina was extremely passionate and active with her community involvement. This list includes the Audubon Society, Daughters of the American Revolution, the Chautauqua Bird Tree and Garden Club, the West Orange Community League and much more.

The Edison Family 

She accomplished all this as well as filling the role of loving and supportive wife to Thomas Edison, one of the greatest inventors and most successful entrepreneurs in American history.

Mina also raised 6 children with Thomas Edison. Thomas Edison lost his first wife, Mary Stilwell Edison at a young age with who he had three children. She passed away in 1884. When Mina married Thomas Edison in 1886, she also became the stepmother to Edison’s three children at the early age of twenty. 

Mina and Thomas Edison also had three children together. All who all went on to build successful careers and each had a profound positive impact on society (check our blog next week for more details on the Edison children). 

Chautauqua Institution Archives

Once we decided to blog on Mina Miller Edison, we reached out to Chautauqua Institution. They graciously connected our team with the Chautauqua Institution Archives.

The Chautauqua Institution Archives, the Oliver Archives Center, contains thousands of letters from Mina corresponding with friends, colleagues and family members. The Chautauqua Institution archivist, Jonathan Schmitz is extremely knowledgeable on the Edison Family. 

It was truly fascinating leafing through dozens of letters. However, this is certainly a far cry from the digital age of texting, emailing, tweeting, snapchatting and instant messaging. For example, the archive hosts thousands of corresponding letters between Mina and her children. Mina kept everything. There was even a receipt from a weekend stay at the Chautauqua Institution legendary hotel, Hotel Athenaeum.

Let’s Connect

Thank you for reading our post on Mina Miller Edison. This blog continues our series on the Thomas Edison Family. Check out our previous blogs on Thomas Edison below:

Over the next few weeks, our blog series on the Edison Family will dig deeper into the life of Mina Miller Edison.

Also, to learn more about Falconer Electronics, please click here.

Lastly, let’s get social! We would love to connect with you on FacebookTwitterGoogle+, and LinkedIn.

The Thomas Edison Family name is well known. Everyone that has ever learned about electricity knows of Thomas Edison. However, how much does anyone really know about the entire Edison family? The facts below can bring the entire Edison family into the spotlight.

Thomas Edison Facts

Facts about Thomas Edison

  • Throughout his life, Thomas only spent 3 months in public school
  • His mother took him out of public school and homeschooled him
  • Also, at the young age of 11, Thomas was already a business entrepreneur
  • His nickname was Al when he worked on the train system
  • He also had a science lab on a train
  • Due to an accident with his lab on a train, Thomas Edison lost his hearing
  • Thomas saved a young boy from being run over by a train
  • Due to the rescue, Thomas become a telegraphist
  • Thomas Edison had a tattoo
  • After teaching Mina Miller Morse Code he proposed marriage. That is also how she answered him with “Yes”
  • Thomas had 6 children: 1 daughter and 2 sons from both of his wives

Mina Miller Edison’s Family Facts

Mina Miller Edison's Family

  • Mina Miller’s father was a co-founder of Chautauqua Institute
  • All of the Miller children grew up visiting their Summer home in the institute
  • Education was very important to the Miller family
  • Therefore, after graduating high school Mina attended Miss Abby H. Johnson’s Home & Day School for Young Ladies in Boston
  • Mina owned the home at Glenmont along with calling herself the “home executive”
  • She also ran the household and staff
  • Furthermore, Mina Miller Edison was the daughter, wife, and mother of inventors
  • Mina Miller was less than 10 years older than Thomas Edison’s eldest child Marion

The Edison Children

  • Thomas Edison’s oldest daughter Marion was married to a German soldier during WWI
  • William, Thomas’s third child with his first wife, also fought in WWI for The United States
  • Edison’s two oldest children had nicknames for terms used in Morse Code: Dot and Dash
  • The three eldest Edison children assumed they could get what they wanted by dropping their famous father’s name
  • Also, Thomas Edison Jr. changed his name from Edison to Willard upon his father’s request.
  • Both of the eldest Edison boys (Thomas and William) turned to farming as professions
  • Madeleine Edison, Mina’s first child (Thomas’s fourth) was the only Edison child to have children of their own
  • The Edison family continued to vacation at Chautauqua Institute throughout their lives

Contact Us

Want to know more about Thomas Edison? Read our blog on Thomas Edison’s Life!

You can also learn more about his inventions. Check out our blog on his Successes and Failures.

Are you interested in more information about Mina Miller and her ties to Chautauqua Institution? Check out our other blog on Mina Miller!

Want to know more about what we do here at Falconer Electronics? Check out the rest of our site!

Also, check out our customer favorite pages  Wire Harness Assembly and Ground Straps.

More Helpful Information on Thomas & Mina Edison

National Park Service

The Chautauqua Daily

Thomas A. Edison Papers from Rutgers University

Edison and Ford Winter Estates

The Edison Museum

Thomas Edison Muckers

t.e. voting machine

Thomas Edison’s Successful Inventions

In the Beginning

Thomas Edison had many inventions. However, in 1868, at the age of 22, Thomas Edison invented an “electrical vote recorder“. This was Edison’s first patent. This recorder was a very simple concept. It was for Congress to record their votes. The recorder was also an electrical system containing a dial for each legislator. Each of these dials would have a “yes” and “no” option. Also, after the votes were made the clerk would record the results. Furthermore, the system would add the votes of both choices to obtain final results.

Edison’s Laboratory

Edison was the first inventor to see invention as far more than simply embodying an idea in a working artifact. His vision encompassed what the twentieth century would call innovation—invention, research, development, and commercialization. In the process, he helped to create a new institution for invention—the industrial research laboratory, which might be considered Edison’s greatest invention. 

Thomas A. Edison Papers

In 1876 Thomas Edison moved his family and resources out of Newark and into Menlo Park New Jersey. There he established a research facility. This facility was the first of its kind. It included top of the line equipment and resources. Therefore, creating new opportunities for other inventors to establish their own labs. Furthermore, Edison’s Menlo Park Lab is thought of as one of his greatest inventions. Along with opening the door for other inventors to create labs, it also gave Edison the perfect place to continue his own work.

Thomas Edison’s Favorite Creation

In 1877 Thomas Edison spent his time inventing his favorite invention. It was the first phonograph. The phonograph was the first stage in recordable music. However, it’s original purpose was to record voices. Edison utilized the vibration of speech. The vibrations created markings on tin foil with a needle. Later he would use the same type marking on cylinders and discs to record music. Edison’s favorite creation was the first step in the recordable music we know today.

Out of the Darkness into the Light

One of the most well-known inventions by Thomas Edison is his incandescent light bulb. However, Edison was not the first inventor to work with electrical lighting. Some inventors were very successful with their lighting inventions. Many of these other inventors were focusing on industrial lighting. Therefore, the real challenge for Edison was to create electrical lighting for home use.

Due to this need, Edison began his search for safe reliable lighting that could be used in homes. Incandescent lighting was the perfect solution. However, it took Edison a year and a half to invent the bulb. Edison had to ensure that it was not only economical but safe to use in a home. The biggest sign of success was with a lamp. It included a filament that was made by carbonizing a thread. This thread allowed the bulb to stay on for thirteen and half hours. Therefore, his work with light bulbs started the electrical system that we know today.

In December 1879 Edison showed how functional his incandescent bulbs were. He established a lighting system and installed it in Menlo Park. Therefore, establishing the first step in the creation of the electric industry. In September 1879 the first commercial power station began its operations. This station provided power and electrical lighting to one square mile. The beginning of The Age of Electricity was its result.

Thomas Edison Inventions: Electric Vote Recorder

Thomas Edison’s Electric Vote Recorder

Thomas Edison Inventions: Incandescent Light Bulb

Thomas Edison’s Incandescent Light Bulb

The Failed Inventions of Thomas Edison

When asked about his failures in an interview Thomas Edison stated:

“I have not failed 10,000 times—I’ve successfully found 10,000 ways that will not work.”

Failure is Not the End

Thomas Edison did not like to refer to his inventions as successes or failures. In the field of inventing, it is possible to get bogged down by creations that don’t turn out the way you want. However, Edison was not one to focus on what went wrong. He would rather focus on what he could learn or improve. His first patent for the Vote Recorder is a specific example of this.

 Electrical Vote Recorder

Thomas Edison was very young when he invented the Vote Recorder. Due to this, Edison thought it was a sure thing. He believed his recorder would make life easier. Therefore, he took his invention to Congress. Due to its efficiency, however, Congress feared voters would not take the time to think through their votes. Therefore, it was promptly denied. Due to Congress’s denial of his first patented invention, Edison could have easily walked away from the profession. However, he didn’t see Congress’s dismissal as an ending to his career or passion.

“Our greatest weakness lies in giving up. The most certain way to succeed is always to try just one more time.” – Thomas Edison

Talking Dolls

The phonograph was Thomas Edison’s favorite invention. He took the time to perfect it. He wanted it to not only record voices but music as well. Edison thought that he could take this technology and implement it into toys. He developed a housing for the machine. It was small enough to be placed inside doll bodies. Edison even had children record the voices for the dolls. This was so they would be more relatable. However, the quality was not great. It was even considered frightening. Due to crackling and hissing families thought that the dolls sounded like monsters. Therefore, his idea for the talking doll did not take off at the time. However, like the talking dolls of today, Edison opened the door for other modern technology.

Electronic Pens

Modern offices all have copiers. However, during Edison’s time, there was no easy way to make multiples of the same work. The only way was to handwrite them. Handwritten copies had disadvantages. Along with misspellings, there was also a concern that the writing would be illegible. Therefore, Edison thought of a better solution. He believed an electric pen could change how offices, schools, and churches conducted business.

Edison combined a small motor and battery with a needle. The motor would then power the needle to move up and down. This movement caused the needle to poke holes through a stencil. Ink could then be rolled over the markings. It was then possible to make multiple copies of one written work.

The mechanics of the pen worked. However, it was heavy to work with. It was also loud for a business or academic environment. Therefore, Edison made improvements. He improved the sound and weight, but it wasn’t enough. The pen required a battery. The battery required maintenance. Therefore, specific chemicals had to be poured into the machine. A process that was very messy.

Tattoo Guns

Edison’s electric pen was not the best match for businesses, schools, and churches. However, it did introduce new possibilities to a different industry. The tattoo industry. He did not hold the patent for the early tattoo gun. However, Edison’s electric pen holds the credit for having a strong influence on the design.

Thomas Edison had a tattoo. It was five dots arranged how the number five is represented on a dice. However, no one is sure where Edison received his tattoo. Many people wonder if he tattooed himself using his own electric pen.



Edison inventions: The Electric Pen

Thomas Edison’s Electric Pen

The Original Tattoo Gun

The Original Tattoo Gun

Concrete, it’s Not Just for Sidewalks

After developing a lightbulb for home use Edison was determined to continue to make life better for others. Edison came up with a way to pre-build pieces of homes out of cement. Therefore, keeping the cost low for struggling families. The idea was to pour the pieces for the houses. Then those pieces could be quickly assembled for those in need of housing. Due to their material, these homes would also be fireproof. However, there was resistance among the communities. The houses were eyesores. Furthermore, his target audience did not like the fact that everyone would know their financial situation.

In addition to creating cost-effective housing, Edison had the belief that he could develop cost-effective furniture. Therefore, Edison’s idea for concrete homes became an idea to create concrete furniture. The belief was that newlyweds wouldn’t want to spend too much on furniture that wouldn’t last. The hopes were that they would flock to buy his cost-effective alternative that would last a lifetime. However, concrete was too expensive to be an alternative for other material. Also, people didn’t like the look of the furniture.

Yankee Stadium

Even though Edison’s idea for concrete homes and furniture didn’t take off it wasn’t a complete failure. Edison’s concrete company held the contract to build Yankee Stadium. Therefore, even though his concrete homes did not work out there was value to his idea of building concrete structures. In addition to Yankee Stadium, the few concrete homes he did sell, still stand today.

The Edison Spirit Phone

Another interest of Thomas Edison’s was the spirit world. He spoke about an invention that was a combination of technology from the telephone and the telegraph. The concept of this new invention was to cross the line between the living and the dead. It was also Edison’s hope that it would make it possible for people to have conversations with the dead.

However, there was never any proof that the invention was real. Even after Edison’s death, no record of a spirit phone was found. Therefore, it has become a belief that there was never any intentions of creating such a device. The only evidence of such a phone was Edison’s mention of it in an interview. This is now seen as being a joke that he pulled.

Even without evidence, there are still people who believe that Edison had such a creation. It is some of those same people, who believe that he kept it to himself. They also believe he never shared his plans with any of his coworkers or fellow inventors. Whether it was real or just a grand joke Edison definitely peaked interest with the possibility of this invention. This is Due to people often being intrigued by the thought of communicating with their passed loved ones.

The Iron Ore Separator

Thomas Edison had multiple inventions. Many of which that can be thought of as failures. However, there is none like his Iron Ore Separator. Edison spent money, time, and resources on developing technology for his separator. The end goal was to be able to separate the iron ore from lower grade ores that were unusable. Edison worked for ten years on his separator project. He invested all of the money he had earned from his work with General Electric. In the end, all of the money he had invested had been for nothing. Edison ended his project when iron ore prices dropped. Also, iron ore became an obsolete substance. If not for his sustainable success of the phonograph Edison would’ve been left with nothing after the separator incident.

Successes and Failures in Inventing

Thomas Edison is seen as one of the greatest inventors that ever lived. He had multiple successes and failures. However, his failures never stopped him. His life was about his inventions. He was continuously seeking answers and solutions. Edison was an inventor until his death. He stuck with his passion for inventing. Even when his inventions didn’t turn out how he thought they would. Also, there were times he was able to change his idea to suit what the situation needed at the time.

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Also, visit our blog about Thomas Edison’s life.

To learn more about our company, please click below:

Helpful Links About Edison’s Life

Links About Edison’s Inventions recently announced that LinkedIn has now grown to 500 million users in over 200 countries. Estimates also show that 227 million LinkedIn users are active on a monthly basis.

As the largest professional social network, are you taking full advantage of the incredible benefits available?

Small manufacturers have been slow to embrace social media including LinkedIn.

This is truly an unprecedented business opportunity.

It is hard to imagine life prior to LinkedIn and we can’t wait to see the new tools available.


We are continuing our blog series on B2B Marketing. Connecting, networking, engaging and creating a healthy sales channel for your business is critical.

Small U. S. Manufacturers are commonly not known for being sales savvy. Many business owners launch a company for various reasons. In many cases, the owner of a small manufacturer is a technician, craftsperson or widget expert. They find themselves tired of working for someone else or felt they could simply do a better job than their past employer.

Solving someone’s problem evolved into a revenue source that eventually became a business. Especially at a custom manufacturer or job shop. These businesses may find themselves with 30-60% of sales with one customer. Therefore, they are extremely vulnerable.

Are You LinkedIn? 

LinkedIn offers the opportunity to expand your network quickly and effectively. This is also a place where you can network and engage in conversations within your industry. You can join groups and reveal your experience and expertise as a problem solver. Particularly to a potential customer who could use your services.

There is an excellent saying that “People pay for what they don’t know”. It can also be said, people pay for what they simply do not want to do.

In the case of a small manufacturer, a customer may be willing to pay for your knowledge and services that you provide. Especially, the resources that you built and accumulated to provide machinery, tools, and expert staff.

It’s time to stop being the best-kept secret. Step out of your comfort zone and start spreading the news that you are open for business. Demonstrate and broadcast that you are a product expert and eager to solve customer problems efficiently and effectively.

Have you read blog posts or watched YouTube videos on LinkedIn best practices?

For example, check out Dennis Brown who is one of the nation’s top experts on executing LinkedIn strategies for small businesses.

Let’s Connect

Thank you for reading our post on LinkedIn for Manufacturers. Of course, we would love to connect with you on LinkedIn (Click Here).

Don’t have a LinkedIn account? Would you like to? Follow this link (Click Here).

This post continues our series on B2BMarketing as well as marketing for New Product Development.

To learn more on Wire Harness Assembly Process, click here.

Also, please connect with us on FacebookTwitter, and Google+.

Wishing you an ELECTRIFYING DAY!



Do you love electronics as much as we do? Do you also have a wicked sense of humor? Enjoy watching awesome videos on electronics as well? In particular, videos delivered with a contagious enthusiasm? Well we have the answer for you. Due to popular demand, you need to tune in to the EEVBlog! (Click here)

What is the EEVBlog? EEVBlog stands for Electronics Engineering Video Blog. A place where there is “No Script, No Fear and All Opinion.”

EEVBlog Host Dave Jones 

The EEVBlog is insanely popular. Host Dave Jones fiercely entertains and educates on everything electronics. The EEVBlog is “an off-the-cuff Video Blog about Electronics Engineering, especially for engineers, hobbyists, enthusiasts, hackers and Makers.”

Dave Jones, from Sydney Australia brings 25+ years of experience as an electronics design engineer.

In addition, his wildly successful YouTube Channel boasts 534,000 subscribers with over 80,000 daily views. Another impressive stat, the EEVBlog Youtube Channel has over 110 million views in total. Wow!

Dave targets a worldwide audience of engineers and electronic enthusiasts. As well as nerds too. Check out this video:

As a manufacturer of electronics, we therefore find the EEVBlog an extremely valuable resource. Especially for our customers designing and developing new products in electronics.

Furthermore, videos and content from Dave Jones are consistently helpful and educational. Most noteworthy, Dave delivers outstanding information with a deep passion that viewers find thoroughly entertaining.

Here are a couple of our favorite videos:

How to Set Up An Electronics Lab

Also “What Do Compliance Logos Mean”?


Are you a beginner just starting out? Another significant benefit with the EEVBlog are the number of tutorials that Dave produces. If you are looking for how-to videos, Dave Jones also offers an outstanding selection. Below includes numerous key videos for beginners:


The EEVBlog also provides an extremely vibrant forum. A place to chat for engineers, product developers and electronics enthusiasts. Topics include beginners, projects, repairs, manufacturing, crowdfunding and much more.  Most noteworthy, this forum engages a world wide audience.

Let’s Connect

Thank you for reading our post on the EEVBlog. This post continues our blog series on New Product Development and Wire Harness Assembly. When you have a brilliant idea for a new product, you need to rely on engineering expertise such as Dave Jones.

By the way, this is our second blog on a friend from “Down Under“. Aussies Rule!!

Also, check out our blog series on B2Bmarketing to help market your new product.

Finally, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!

Brian Dean

Struggling with Internet Marketing and SEO? Overwhelmed? Frustrated? Do you find link building daunting? Well help is just a click away. Check out Brian Dean at

Brian Dean is a MUST read for all small business owners. Especially for entrepreneurs attempting to tackle SEO strategies on their own. Brian Dean delivers an enormous amount of priceless information. He is an SEO guru, particularly helping clients with link building strategies.

Actually, we found executing SEO strategies with the guidance from Brian Dean invaluable. Since November 2017, our web traffic increased by over 400%. THANK YOU BRIAN!!

Brian Dean Link Building Strategies 

Brian Dean offers an extensive education on link building. Yet, he does so in a simplistic nature. In addition, he provides a wealth of executable strategies. For example check out this post on Link Building: LINK BUILDING FOR SEO: The Definitive Guide (2018 Update)

He breaks down the process in easy steps. His posts include clear descriptions and photos as well as concise directions on how to achieve keyword ranking goals.

Brian Dean Powerful Guides 

Check out the list below of SEO Guides on

Need help with SEO for Ecommerce? The link below provides a comprehensive guide for Ecommerce:

Brian Dean YouTube Channel 

Prefer videos over reading blog posts. No problem. Check out Brian’s extensive video library on his YouTube Channel.

He provides all of this priceless information for FREE. FREE! Just Amazing!!

Here is another outstanding video on “How to Get Higher Google Rankings in 2018 [New Checklist]”

B2B Marketing for Manufacturers

We frequently assist small business owners with New Product Development, primarily with Wire Harness Assemblies. However, developing the product is only half the battle. Marketing your product and business aggressively is critical. Entrepreneurs and small business owners must take full advantage of every resource possible.  Especially in these competitive times. That is why following strategies from experts like Brian Dean at Backlinko becomes so important.

Let’s Connect

Finally, thank you for reading our blog on Brian Dean. Please check back for our continued blog post series on B2B Marketing.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!


As an electronics custom manufacturer for over 30 years, we have watched many trends come and go. This week we discussed the continued steady growth with B2B E-commerce. Of course, this trend shows no signs of slowing down anytime soon.

So we decided to join the e-commerce party. Actually, we decided to jump in feet first. Going through the process of instituting a new e-commerce store was especially thrilling for our team.

Many small businesses find embracing new technology challenging.  Utilizing unfamiliar technology to develop a new sales channel takes a team effort. Especially since creating a new method of doing business requires instituting a cultural shift. This process can be scary as well as exciting at the same time.

Yet, since opening our e-commerce store, we have opened new doors that previously never existed for us. Being the “under the radar” is no longer an option in the digital age.

E-commerce Tips for Manufacturers 

In continuing our series on B2B Marketing, creating a sales channel is critical for product sustainability. If you consider launching your own e-commerce store, below includes several tips to consider:

  1. Domain name
  2. Logo
  3. Select web designer – find someone with experience – someone you trust – someone with a proven track record.
  4. Select a shopping cart – your designer will have the experience and expertise to walk you through this process
  5. Credit card processor
  6. SSL Certificate
  7. Designated email for customer service and product inquiries
  8. Consider establishing a dedicated phone line on the website
  9. Infrastructure in place to process orders quickly – fast turnaround time is paramount
  10. Talk with reps from UPS, FEDEX, and USPS regarding discounts and shipping options
Let’s Connect

Thank you for reading this post on e-commerce. This post continues our blog series on New Product Development and B2B Marketing. Also check out our post on social media for manufacturers.

Lastly for more info on electronics manufacturing, please connect with us on Facebook, TwitterGoogle+, and LinkedIn.

B2B Ecommerce

B2B Ecommerce is an explosive growth market showing no signs of slowing down anytime soon. This is exciting on two fronts. Not only for the tremendous growth opportunities for B2B companies but also the sheer size of the market. Forrester predicts a compounded annual growth rate of 7.4 % while reaching $1.2 trillion by 2021.

However, ecommerce and social media are significant forces that have had a huge impact on small U.S. manufacturers in recent years. Most major buying decisions start with a search on the Internet and this is now hitting manufacturers hard. For example, Forrester also predicts B2B Ecommerce buyers conducting research on products will dramatically increase as well.  From 38% to 55% over the next three years. There are incredible opportunities for small U.S. manufacturers to exploit in this exploding global market. Yet, many small manufacturers struggle with executing search strategies while also maintaining a healthy web presence..B2B ecommerce

Problem or Opportunity

It can be extremely expensive, challenging and frustrating for a small manufacturer to create a robust company website.  As well as properly attack keyword search results and social media marketing strategies.

Social media allows a company to engage and respond immediately to customers on a much more personal level. This has been a significant problem for small U.S. manufacturers who continue to struggle with social media marketing strategies.  A company only has one chance to make a great first impression. It usually starts with their website and social media platforms.

American manufacturing is absolutely essential to the U.S. economy. Manufacturing in the U.S. as a stand-alone entity would be considered the 9th largest economy in the world. In addition, according to the National Association of Manufacturers, there are over 200,000 U.S. manufacturers with 20 employees or less (National Association of Manufacturers, 2016).

Digital Immigrants Struggle with Technology 

A large number of owners of small manufacturers fall into the generation of either baby boomers or Generation X. These individuals are digital immigrants (born before 1980) who severely struggle with embracing technology. This includes ecommerce and social media marketing strategies.

Social media has completely changed the landscape for business-to-business communication across the supply chain. Especially through distribution channels.  Many small businesses are discovering that ignoring social media is extremely dangerous for a business of any size.

B2B Ecommerce at Falconer Electronics 

Falconer Electronics recently launched a brand new B2B Ecommerce store. This has been an extremely exciting process for our company. Being a traditional manufacturer for over 30+ years, this was certainly a challenging task. Embracing new technology is critical for small businesses to remain competitive and profitable.

Let’s Connect

Thank you for reading our blog on B2B Ecommerce. As we continue our series on B2B Marketing, executing marketing strategies is critical. In addition, here are a couple helpful posts on social media platforms and blogging for your business.

Looking for amazing resources to dig deeper into internet marketing? Check out Neil Patel and Darren Rowse at ProBlogger.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!





In 2008, when blogging was still relatively new, I purchased a book (pic below) about blogging. In attempt to figure out how to approach this new fad at the time. The title of the book, “ProBlogger: Secrets for Blogging Your Way to a Six-Figure Income“.

Turns out blogging was not a fad at all and is here to stay. At least for the foreseeable future. The author of that AMAZING book was none other than Darren Rowse, the ProBlogger himself. A gentleman from the “land down under“.


Well to fast forward, Darren was a huge help then and even a bigger help today.

Our team at Falconer Electronics owes a big thank you to Darren Rowse at He is not only an expert blogger and author, Darren Rowse is an incredible educator and powerful resource.

Tackling internet marketing and social media strategies can be challenging. Especially for a small U.S. manufacturer. Though we are far from blogging experts, we excitingly follow THE BLOG EXPERT to help achieve our goals.

Thanks to following tips and advice from Darren, our website traffic increased by 400% since November 2017.

Follow the ProBlogger 

Looking to take your blog to the next level? Darren Rowse delivers a wealth of information on his blog about……blogging. Thus, he is the ProBlogger. In addition to his expertise, his passion resonates with every post.

For example, check out this link to our favorite post from Darren where he loaded this post with tons of helpful links: How to Write Great Blog Content.

Also, simply follow Darren on Twitter to catch daily nuggets (along with his nearly 250,000 other followers).

In addition, sign up for Darren’s email newsletter (along with his 300,000 subscribers). Especially since the ProBlogger offers an endless amount of tips, suggestions and advice to develop your craft. You will quickly become a blogging guru.

Just Getting Started with Blogging?

Looking to start a blog? Check out the ProBlogger “Start Here” page.

Darren also explains how to start a blog in five easy steps that include:

  1. Choose your blogging platform
  2. Secure a domain name and get hosting in place with Bluehost
  3. Configure your blog
  4. Design your blog
  5. Start creating useful content that serves readers

ProBlogger Videos

Prefer watching videos? Check out the ProBlogger YouTube channel for hundreds of videos on blogging tips and strategies. Below is an outstanding recent video from ProBlogger on 9 Ways to Accelerate the Growth of Your Blog:

Blogging eBooks

As mentioned above, Darren writes fantastic books. Lots of books in fact. So if you are looking to dig deeper beyond Darren’s newsletter and social media posts, check out the impressive arsenal of book titles that Darren Rowse offers below:

ProBlogger Podcast

Last but not least, check out The ProBlogger Podcast which offers a massive library with a selection that includes hundreds of podcasts. Here is an excellent podcast on Growing Your Blog’s Income.

Let’s Connect

Thank you for reading our blog on ProBlogger.

Most of all, we appreciate you taking time to read our recognition and SPECIAL THANKS TO DARREN ROWSE. Internet Marketing experts such as Darren help make our jobs much easier.

This blog continues our blog series on B2B Marketing. Especially for those working on New Product Development. Also, check out our other recent blogs.

Lastly, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!

Bald Engineer

As electronics geeks, we thoroughly enjoy following James Lewis (aka: the Bald Engineer). James delivers outstanding  information, tips and product reviews on his electronics blog. If you are an electronics junkie like us, you will find his information invaluable.

The tagline on his website: “Electronics tutorials in plain simple English. Our goal is to add the engineer to nerd to create a world of Enginerds.” Otherwise as James simply states, “Electronics Stuff for Enginerds.”

Actually my affection for James Lewis runs deep for two reasons. Not only due to our mutual passion for electronics but also being fellow bald guy.

The Bald Engineer

The Bald Engineer Covers Electronic Basics 

Just a beginner in electronics? Need to learn the basics? No problem!

James provides an incredible arsenal of helpful information on electronics basics: (

My personal favorite is his post on LED basics: LED Tutorial – Learn the basics

More Electronic Basics

In addition, below includes several informative blog posts covering more “Electronic Basics”:

AC/DC – More Than Just a Killer Band

James has a fantastic video library on YouTube that serves more than 80,000 subscribers with millions of views.

For example, in this video below James explains that AC/DC is much more than a legendary rock band. Which honestly came as a big surprise to me. Growing up in the 80’s, I just figured that electricity must have been named after the rock band. James clears things up for us AC/DC fans.

Newsletter and Free eBook 

You can join the nearly 90,000 subscribers when you sign up to receive the Bald Engineer newsletter. Just recently, James sent out a cool post on: “Oscilloscope Probes Primer – Why so many types? Compare Passive, Active, High Voltage, and Current Probes”.

 You can also receive a FREE copy of his eBook, “On the Bald Engineer Electronics Bench”. This book is an excellent resource and offers helpful tidbits.

Product Reviews 

Searching for electronics product reviews? The Bald Engineer has you covered there as well.

Since we do plenty of soldering, we particularly enjoyed this review on “Fume Extraction Unit for soldering applications” (found on

Here is another great review on “Pi Cap Hands On Review: My first impressions of a Raspberry Pi capacitive touch hat”.

Let’s Connect 

Thank you so much for reading our blog post on James Lewis and his alias, the Bald Engineer.

As we continue our blog series on helping clients with New Product Development, the Bald Engineer website is an excellent resource.

For those adventurers into creating new electronics requiring a wire harness assembly, check out our new Wire Harness Estimator for a Fast & Easy Estimate.

In addition, as you work on bringing new products to market, check out our blog series on B2B Marketing to help market your new products.

Lastly, we would love to connect with you on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!

glowing keyboard

blogging on a laptop with notebook and coffee

The History of Blogging

The internet has been around since the 80’s. However, blogging was first established in the mid 90’s. The term “blog” wasn’t recognized back then. Due to this, the first “blog” was a personal homepage of a college student. In the later 1990’s the term “weblog” was introduced. This term was a shorter version of the term “logging the web”. Additionally, we all know that wasn’t the last time this term would be shortened. Today we know these “weblogs” as “blogs”.

The Art of Writing an SEO Friendly Blog on WordPress

There are numerous types of blogs. From personal blogs to professional blogs they all serve their own purpose. However, what is one thing that all blogs have in common? They are all trying to share some form of information. Also, what sets some blogs apart from others? The most obvious is if they can follow all of the general rules of blogging. Another sign of success for a blog is how many readers it has.

Specifically, with a WordPress blog, there are two main categories that will lead to the best results, “Readability” and “SEO”.


Readability is a very important aspect of a successful blog. When writing a blog, the main goal is to have others read what you are writing. In order to do that there are some guidelines that should be followed. Below is a brief description of each part of achieving high readability.

What is a Copy Score and Flesh Reading Ease Test

The Flesh Reading Ease Test is affected by how easy your text is to follow and read. This goes along hand and hand with the copy score of your blog. What affects your Flesh Reading score? First off, your sentence length. Why would sentence length affect readability? Longer sentences mean extra words. Furthermore, these extra words are seen as fillers that are not needed.

Along with shorter sentences, the Flesh Reading Ease Test is looking at the individual words in sentences. In blogging, using hard to understand words hurts you. Therefore, you want to keep all of your information as concise and to the point as possible. Furthermore, the Flesh Reading is hoping to encourage blogs written without the extra fluff. It is also encouraging you the writer to take the time to find the best way to talk about your subject.

The Number of Words in Your Paragraphs

The number of words you use may seem like a trivial thing to think about. However, the more words you are using the longer you are taking to make your point. Along with the Flesh Reading Ease Test, shorter paragraphs are also ideal. Therefore, if you can use one sentence to describe your subject that is preferable to using multiple sentences.

Use of Transition Words

Why are transition words so important? Transition words help the flow of your blog. Instead of jumping from one thought to another, a transition word will help tie two thoughts or sentences together. Therefore, helping the reader to continue following the path that you are lying down for them. Also, the use of transition words helps you to really see if your sentences really fit together. If you cannot make a tie from one sentence to another there may be a need to rethink your sentence placement.

How Passive is the Voice You Use in Your Writing

What is Passive Voice?

Passive voice occurs if the noun or noun phrase that would be the object of an active sentence (such as Yoast SEO calculates your SEO score) appears as the subject of a sentence with passive voice ( The SEO score is calculated by Yoast SEO). In figure 1, we give more examples of passive voice and give better alternatives.

The above is the definition of Passive Voice by Yoast SEO. However, what does it mean exactly? In our work with blogging, we have discovered that the simplest way to get rid of Passive Voice is to make your sentences in the present tense. Therefore, instead of using words that end in “ed” use their present tense counterparts. Below are some examples of this.

Passive voice Better alternatives
This product can be bought in our webshop. Customers can buy this product in our webshop.
The bags are checked by a security employee. A security employee checks the bags.
The employees are informed about their financial contribution. The manager informs his employees about their financial contribution.
All our posts are checked by a colleague. A colleague checks all our posts.

As you can see from the examples above keeping your writing in the present tense is important. However, another thing that is just as important is to keep your point of view consistent. For example, this blog is written as if we are talking specifically to the reader, you. Therefore, you as the reader feel as if this more of a conversation than just cold instructions. Also, by keeping the same point of view throughout the entire blog you keep up that same flow that we spoke about previously.


Much like readability, SEO is also important in blog writing. However, what exactly is SEO? SEO is an acronym for “Search Engine Optimization”. What does that mean exactly? Also, why is this important when writing a blog? In order to understand why it is important, you need to understand all of the pieces to achieve good SEO. Below we have broken down each of the aspects of SEO.

Focusing on a Keyword

What is a keyword? A Keyword is a single word or short phrase that you want to be the main idea of your blog. For instance, in this blog, our keyword is “blogging”. Therefore, this word is what the basis of our entire blog is on. Other examples we have used in previous blogs are “LED Lighting”, “Certification”, and “Wire Harness”. The use of a keyword can be difficult.

The SEO has certain criteria in order to keep all of their requirements in the green. Furthermore, with keywords, they require that your keyword is present in your title, at least one of your headers, and also be used in the first paragraph of your text. However, they do not want that one word used too often and will penalize you if you overuse it. Also, SEO prefers that when your keyword is used in your title and header that it be as close to the beginning as possible. Therefore, we usually try to keep our keywords as the first or second word of our title and we also try to place it in the first heading within our blog.

Creating the Perfect Title

Creating the perfect title can be a challenging first step. It is often helpful to write up some notes about what you want your blog to be about. After you have an idea of what your blog needs to say it will make writing the title and choosing your keyword easier. As we stated above, in the title you want to be sure to include your keyword. Also, if possible you want to keep it close to the beginning.

Your title also needs to be long enough in length to meet the SEO criteria. That being said, you need to make sure that it isn’t too long. The best way that we have found to achieve the perfect length is to write your title then bring that title into the “snippet preview”. WordPress makes this part easy. When you copy your title into the previewer it has a color bar beneath it that will change as you add or take away words. A red bar means that you either have too few or too many characters. As you adjust your wording that color bar will hopefully change to green.

Why is a Meta Description Important

First off, we should describe what a Meta Description is. The Meta Description is the blog equivalent to a blurb on the back of a book. This small snippet gives anyone that reads it an idea of what your blog is about. Also, you want to be able to draw in a reader, just like with a book. If your Meta Description isn’t interesting you will lose any potential readers before they even get to your blog.

Meta Descriptions are used by search engines. This is also why you want to include your keyword in your Meta Description as well as the other places within your blog. There is a set length for a Meta Description of 160 characters including spaces and punctuation. Due to this specification, you want to keep your descriptions as short and to the point as possible while still providing important information. Also, you want to do all of this while still drawing potential readers to your blog. Finding that balance is important to having a successful blog.

Adding Images and Videos to a Blog

Everyone knows that we live in a visual world. Pictures and videos draw in an audience. However, you don’t want to just put any picture or video on your blog. You want to have images that are related to your subject.

For example, if you are writing a blog on sharks. You would not want to include pictures of your best friend and their dog at the park. The same goes for any videos you want to include. Therefore, any pictures or videos that you use need to be applicable to what your blog is about.

Also, if you are using videos in your blogging there are some important things to look out for
  • If you are using a YouTube video check the suggested videos that will come up after your chosen video. There are times when the suggested next videos are not professional in nature. Due to their content, they could affect the brand you are trying to establish, therefore, affecting the view your potential customers have of your business.
  • The timing of your video is important as well. You do not want part of your video cut off due to the version you’re using.
  • Also, be aware of the quality of your video. If the picture quality is low or the volume is problematic no one is going to want to continue to watch your content.

For example, below includes an outstanding video from Neil Patel on “7 Blogging Tips That Will Make Your Blog Successful”:

What are Good Links?

There are two different types of links you want to include in your blogs, internal and outbound links. What is the difference between them?

Internal Links

These are links that go back to another part of your own website. Therefore, a link to another blog on your website, a page of your website, or a picture or video on your website. Importantly, it is a link back to another part of your own website.

Outbound Links

Outbound Links are links to anywhere other than your own blog. It can be a link to reference website, your own social media, outside pictures and videos, or to an outside website or blog that is applicable to what you are blogging about. However, you want to be careful when using links to outside websites that are not under your control. There is the potential that these sites can be corrupted, deleted, or that their content will change to no longer apply to your subject. Also, if you choose to use a link to a video you want to be aware of the factors we discussed previously.

Words Matter

When writing a blog, it is important to say everything that you feel is important to your subject. Whether that is facts, details, or any extra information that you think would interest your audience. You want to keep your blog informative but also, interesting to your readers.

SEO is concerned about how many words you use. The ideal minimum of words SEO likes is 300. That does not, however, mean that you can’t go over that amount. However, you want to continue to make sure that your content continues to be relevant to your subject. Also, each of the points in our “readability” section will help your SEO. The readability and SEO work together to give you guidelines for creating a blog that your audience wants to read.

Helpful Reminders for Your Blogging Experience

What are Alt Texts

When using images in your blog SEO wants those images to contain “Alt Texts”. How can you include these however if you don’t know what they are or what they do? Alt Texts should be a brief description of your image. These descriptions are actually helpful to any of your audience that has visual difficulties or impairments. You want to make sure that any reader of your blog can get every point you are trying to make, even with the images that you have chosen to use.

Choosing a Category

Choosing a category is important. This is stating that that is specifically what your blog is about. Again, if you think of the example of a blog about sharks you could categorize that as being “Sea life”. Therefore, if you continue blogging about different sea life you can have them all in the same category. This makes it easier to search through your blogs. Also, this is helpful when you want people to be able to look up your blogs by their broader subjects.

Useful Tags

You want to include tags in your blogging. These tags target specific pieces of your blog. While the “category” of your blog designates your entire blog as being about a specific thing a tag is like the individual index within your blog of important points.

Why are Links Helpful

Links are helpful to the success of your blog because they create more roads back to you. If you can get other websites to link back your site or blog that is another road back to you. Picture the internet as a town full of roads and each house and building is a website. The more roads to your building the easier it is for your customers to arrive at your door. However, each webpage, blog, video, and product that has a connection to your website is also a road to your door. Each connecting link to and from different sites is another connection for potential customers and readers to find you.

Amazing Blogging Resources

Let’s Connect

Thank you for reading our “WordPress Blogging Guide for Manufacturers”. For more information, check out our blog series on New Product Development. In addition, check out blog series on B2B Marketing.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Some of Our Favorite Blogs on Wire Harness Manufacturing:

Wire Harness Manufacturing Terms, Tools, and Tips of the Trade

Build Your Business Tips: Selecting a Wire Harness Manufacturer

Instant Wire Harness Estimate: Your Step By Step Guide

Neil Patel

If you are new to Internet Marketing and Social Media for your business, you must follow marketing guru Neil Patel. Additionally, even if you are a seasoned veteran with online marketing strategies, you should still follow Neil Patel as well.

You will find information from Neil Patel priceless!

According to the bio on his website (click here), Neil Patel has built an extremely impressive background:

  • New York Times best selling author
  • Wall Street Journal labels Neil Patel as a Top Influencer on the web
  • Forbes calls him a Top 10 Marketer
  • Entrepreneur Magazine declares his firm one of the 100 most brilliant companies
  • Neil was recognized as a top 100 entrepreneur by the age of 30 by President Obama
  • The United Nations ranked Neil as a Top 100 Entrepreneur under the age of 35

Neil Patel Blogging Tips  

A great deal of thanks goes to Neil Patel for offering guidance on blogging. By following his easy-to-understand blogging strategies, our website traffic increased 400% since November 2017.

Neil Patel offers an overabundance of FREE tips on his blog and email newsletter as well as all of his social media platforms. Neil delivers a constant and consistent treasure of information.

If you are just a beginner, check out this link on “how to start a blog”:

Click below to view Neil explain “SEO For Beginners”:

For more experienced bloggers, Neil Patel offers a wealth of helpful tips:

Tons of E-commerce Tips

Having recently launched an E-commerce store, Neil’s E-commerce tips deliver tremendous benefits as well. In particular, you will find this e-commerce post extremely valuable: The Ultimate Guide to Social Media For E-commerce

Below includes additional e-commerce posts that we found as a big help:

Click below to watch Neil explain “7 Ways to Grow E-commerce Sales by 50%”:

B2B Marketing for Manufacturers 

Why is an electronics manufacturer blogging about Neil Patel? We are glad you asked.

As a small business, many of our customers are also small businesses. We work closely with manufacturers who develop and market innovative new products. Many small businesses struggle with tackling Internet Marketing strategies. These strategies are new to our team as well. However, as we have plunged into E-commerce and Inbound Marketing, we find that Neil Patel provides invaluable information.

Our recent blog series on New Product Development discussed individuals and companies bringing a new product to market. Unfortunately that is only half the battle. Marketing the product as well as creating a sustainable and profitable business model solidifies the new product. Neil Patel certainly provides the necessary tips and strategies to help you hit your goals with bringing a new product to market.

Follow Neil Patel on Social Media

Lastly, the list below include links to social media sites for Neil:

Let’s Connect

Thank you so much for reading our blog post on Neil Patel. Please check out our blog series on B2B Marketing.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!

Man surfing social media

Why use social media you may ask? In particular, our friends in manufacturing. There are many ways to utilize social media websites for your business. They are free to use and can be a great marketing tool to get your information out. The content posted on each platform can be informative or even funny to get people to know what kind of business you have.

We work with many small manufacturers. In discussions, these manufacturers share they commonly struggle with tackling new Social Media Marketing strategies. To follow up on our recent blog series on New Product Development, we have started a new blog series on B2B Marketing.

For those new to social media efforts, we decided to offer a quick snapshot of each social media platform that we currently utilize. Particularly for those in manufacturing who are eager to jump on board.

Social Media Sites

FacebookFacebook Logo social media

There are many different ways to utilize Facebook for a business. Pages can be created by just a click of a button, and be a great place to show what your business is all about. You can include information about business hours, location, contact information, and some history of the company.

Here are some advantages to using Facebook:

  • Free (our favorite word)
  • Easy to use
  • Ability to schedule and edit posts
  • Multiple people can create posts
  • People can like, react, comment, and share posts

Here is a link to Our Facebook page.

LinkedIn Logo Social MediaLinkedIn

What is LinkedIn you might ask? LinkedIn is a professional networking site helping to expand your professional profile and network. This is a great site to really expand on what your business has to offer.  The site has more established business professionals on it, so the content can be more technical and industry based.

Here are some advantages to using LinkedIn:

  • Free (still our favorite word)
  • Easy to navigate
  • People can like, comment and share posts
  • Ability to track:
    • Followers
    • Post impressions
    • Engagement
    • Click-Through Rate

Here is a link to Our LinkedIn Page. 

Bird-- Twitter logo, Social MediaTwitter

This social media platform can be used in multiple ways to help with your business. This platform is different because it is less formal. Twitter uses Microblogging, which is a combination of blogging and instant messaging that allows users to create short messages to be posted and shared with an audience online.

Here are some advantages to using Twitter:

  • Free (did we mention this is our favorite word)
  • Only have 280 characters to say what you want
  • Use of Hashtags
  • Worldwide, international coverage
  • Less intrusive

Here is a link to Our Twitter Page. 

Hootsuite logo with bird, social mediaHootsuite

Hootsuite? What is that? Well, Hootsuite is the best way to manage your social platforms. It is a great tool in order to schedule posts on LinkedIn, Facebook, Twitter, Instagram, Google+, WordPress, and YouTube. This site allows you to monitor those platforms as well as post on them. This is great for someone just getting started in the social media world!

Here are some advantages of using HootSuite:

  • Free for:
    • 3 social platforms
    • basic analytics
    • up to 30 scheduled posts at a time
  • Ability to schedule posts
  • Post both pictures and plain text on whatever platform you may be using

Wanna give it a try? Check it out:

YouTube Logo Play button, social mediaYouTube

Everyone uses YouTube to look up those funny cat videos and silly pranks people are talking about, but have you ever tried it for your business? This is a great site to be able to try out new commercial ideas or even to show off what your business has to offer. Videos speak louder than words.

Here are some advantages of using YouTube:

  • Free, great way to try out new ideas
  • Ability to track:
    • Views
    • Comments
    • Likes
    • Watch time
  • Feedback on those new ideas

Here is a link to Our YouTube page.

Quora Logo, Social mediaQuora

Quora is a place to gain and share knowledge. It’s a platform to ask questions and connect with people who contribute unique insights and quality answers. It’s less tangible than Google pay-per-click advertising and not as creatively appealing as a video project.

Some advantages of using Quora:

  • Allows for collaboration of thoughts
  • Answer question related to your business
    • Including:
  • Free website (Seeing a theme here?)
  • Wide range of people
  • Products and features

Here is a link to Our Quora page.

Google plus logo, social mediaGoogle +

By a show of hands, how many people know what Google+ is? Well, we LOVE it! Google + (plus) is a social networking site made by Google. This site really focuses on data, connections, and people.  This allows people to connect and share information with friends and other businesses.

Here are some advantages of using Google +:

  • Just need a Google account to have access
  • Easy to post
  • Linked to Google, so if your posts are related to a search they could show up.
  • Can start Collections, which can separate blogs or other posts into categories
  • One last time, our favorite word, Free

Here is a link to Our Google+ Page

Let’s Connect

Thank you for reading our post on Social Media platforms. As we continue our series on B2B Marketing, please check back for additional posts on social media marketing strategies for manufacturers.



Inbound marketing

Inbound Marketing with protocol 80

Falconer Electronics had the privilege of working with protocol 80 this past year. This program was made possible through a partnered effort with the Small Business Development Center (SBDC) at Jamestown Community College. The program provided the guidance to kick-start a new Inbound Marketing initiative. The entire staff at protocol 80 far exceeded our expectations. Owners Josh Curcio and Donny Kemick along with their team are true experts in Inbound Marketing strategies.

Inbound marketingBeing a custom manufacturer since 1985, our company was built on personal relationships while making connections through word of mouth. Keys to our long-term success includes solving customer problems with high satisfaction levels.

Over 0ur 30+ year history, the world has changed drastically with technology and modern methods of communication. In particular, Inbound Marketing and social media. As with many manufacturers, our company was slow to adjust.

Our staff was eager and excited to jump into this project with protocol 80. Their team specializes in B2B Inbound Marketing. In particular, their expertise targets working with small manufacturers who struggle with digital marketing and social media engagement.

The team at protocol 80 also provided the necessary guidance to understand the entire customer purchasing process. Starting with creating a customer persona, walking through the buyer’s journey, mapping the sales process and maintaining customer engagement.

They educated our staff on identifying social media platforms that best suited our target market. This is extremely important for a company with digital immigrants targeting many digital immigrants. The protocol 80 team were helpful in communicating our company message as well as finding potential clients to engage.

New E-commerce Store 

Thanks to the new found tools and marketing ammunition that protocol 80 provided, it was decided to aggressively expand and diversify. This past year we launched a brand new e-commerce store which includes a proprietary product line of magnetic work lights, ground straps, LED flashing lights and commercial power strips.

Now businesses and consumers alike have the opportunity to purchase directly from the manufacturer. New customers include a Fortune 500 company (actually top 300) that is brightening their day with brand new magnetic spotlights. LED lights shipped to Puerto Rico after the horrible hurricane. Trouble lights shipped to John in Syracuse who loves to tinker in his garage. An industrial supplier now offering our Power Strips to government agencies. Also, we recently received an RFQ for tens of thousands of Ground Straps for a major manufacturer in the U.S.

Wire Harness Estimator 

Another big leap of faith for our company was launching the brand new Falconer Electronics Wire Harness Estimator. This program offers customers the ability to receive an estimate within minutes. This process used to take hours or even days.

This fantastic tool makes it simple and easy for new customers to gather pricing information. For example, a major solar company needed pricing and wire harnesses quickly. The Wire Harness Estimator allowed them to gather pricing fast and easy for their project. They are now a valued customer.


Lastly, under the guidance from protocol 80, our company started blogging this past year. Being extremely tentative, we started slowly by blogging once a month. Then up to once a week. Now our goal is 6-8 blogs per month.

Our staff is thoroughly enjoying the process and we are having fun creating valuable content to connect with new customers. As a result, traffic to our website has increased dramatically (400% since November). Therefore, the increase in traffic brought numerous new leads and new sales started rolling in over the past few months.

A Big Thanks to protocol 80 

We truly feel this newfound strategy delivers an unlimited opportunity for Falconer Electronics. Therefore, we owe a huge debt of gratitude to Josh Curcio, Ashley Wilson-Rew and the rest of the protocol 80 team. They provided the tools, knowledge, and resources to modernize our company.

Bottom line, we find p80 priceless. Especially facing increasingly intense global competition.

Let’s Connect

Thank you for reading our post on protocol 80. This post begins our blog series on B2B Marketing to support recent posts on New Product Development.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!


Wire Harness Estimate

When it comes to gathering a wire harness estimate and quote from various suppliers, the process can cause a lot of frustration. Slow response times from vendors negatively impact your deadlines. Furthermore, it can impact your credibility with customers. Delays also hurt profits.

Therefore, our goal is to save our customers as much time and money as possible. As a Wire Harness Manufacturer, many of our customers commented that they would love a tool where they could capture a Wire Harness Estimate immediately. Right Now!

We all have the same 24 hours in a day. There are no competitive advantages over time. Time is money. Especially since you have thousands of tasks to conquer during each work day. Maximizing efficiency is crucial to your success.

So we went to work with our programmer to create a solution. In particular, a solution that would provide a Wire Harness Estimate as quickly as possible.

The result:

The FEI Wire Harness Estimator 

Receive Your Wire Harness Estimate Instantly 

The FEI Wire Harness Estimator offers an instant Wire Harness Estimate. Perfect when seeking a Wire Harness Estimate or when you just need a ballpark price, pronto.

The brand new online FEI Wire Harness Estimator allows buyers, product designers, and engineers the ability to enter the specs of a wire harness assembly quickly and easily. This straightforward approach eliminates the need to wait days or even weeks for pricing out your estimate.

This tool also works perfectly for companies building a prototype or new product design. As discussed in our New Product Development Series, gathering product information and pricing is critical to moving your project forward.

Fast & Easy to Use 

The FEI Wire Harness Estimator delivers an estimated cost of your wire harness assembly within seconds of submission. It arrives directly to your email. Therefore, you can utilize the simplistic step by step process down below to select each item you require for your wire harness.

First, you can select:

Additionally, are you looking for connectors or other items, not on the list? No problem! All you need to do is enter the manufacturer part number. The FEI Wire Harness Estimator adds that item to the Wire Harness Estimate.

Lastly, you can finalize your estimate with any add-ons you need. Extras such as a spiral wrap, expandable sleeving, wire ties, heat shrink, labels, and flags can all be added.

No Commitments & No Obligation 

There is no commitments or obligations for you to purchase your harnesses from us.

The only requirement is your name and email address. After you fill out all of the required steps you will instantly receive an email with your estimate.

However, the Wire Harness Estimate does NOT represent a formal quote. Yet, this is an outstanding opportunity to provide a shortcut for you to capture a Wire Harness Estimate or a ballpark price for your new Wire Harness Assembly.

Also, for detailed pricing on quantity breaks or a formal quote, you are welcome to submit a drawing and a request for proposal. Afterward, a team member from Falconer Electronics will contact you with an actual quote fitting your timeline and quantity.

You can also call 716-665-4176 or email [email protected] with any questions. We have specialists to walk you through the process.

Furthermore, there is NO MINIMUM requirement and we welcome customers of all sizes. Therefore, you do not have to be part of a large company or even plan on making a large order. We encourage orders of any size.

Step by Step Guide to the FEI Wire Harness Estimator

Below offers a step by step process when using the FEI Wire Harness Estimator:

Step 1) Select Wire Type 

Wire Harness Estimate


You may select multiple wires – Click “Add to Estimate” after each selection.

Options include:

Wire Stranded

  • Available Colors – Black, White, Green, Red, Blue, Yellow, Brown
  • Available Gauges – 6, 8, 10, 12, 14, 16, 18, 20, 22

Flexible Ground Braid 

  • Uninsulated
  • 1/4″ and 1/2″

Ribbon Cable – Gray

  • Available Color – Gray or Color-coded
  • Conductor – 10, 14, 16, 20, 26, 40

THHN – Solid 

  • Available Color – Black, White, Green, Red, Gray, Orange
  • Available Gauge – 12 Gauge Only

THHN – Strand

  • Available Colors – Black, White, Green
  • Available Gauge – 12 Gauge Only

Select Length – The TOTAL length of wire required for a single assembly – This also applies for multiple wires. Select the length of each wire.


The Estimator allows you to Add multiple wires.

Review your selection – if ready to proceed – click “NEXT STEP”.


STEP 2) Select the Number of Individual Wires 

Wire Harness Estimate

This section will include the TOTAL number of Individual Wires in your Wire Harness Estimate.


STEP 3) Select Your Terminal 

Wire Harness Estimate

This section allows you the opportunity to select a specific manufacturer part number. Therefore, enter the manufacturer part number in the space provided and hit SEARCH. Furthermore, the product will populate into the Wire Harness Estimate.

Therefore, if your specific part number is not available, you may select from the list of “house” parts below:

  • Ring Terminal
  • Fork Terminal
  • Quick Connect/Disconnect Terminals
  • Also, Ferrules Terminal

Select Quantity (for a Single Wire Harness)


In addition, you may add multiple terminals and hit “ADD TO ESTIMATE” each time



STEP 4) Select Add-ons 

Wire Harness Estimate

  • Spiral Wrap
  • Expandable Sleeving
  • Wire Ties
  • Heat Shrink
  • Wire Labels
  • Wire Flags

Enter Length in inches or Quantity for all of the above as is applicable.


Also, you may add multiple Add-ons in this section. Also, please remember to hit “ADD TO ESTIMATE” after each selection.



STEP 5) Component Request 

Wire Harness Estimate

Furthermore, this section allows you the opportunity to add any other components or helpful notes that will help determine your Wire Harness Estimate.

Also, any items added to the “Components Request” section will NOT be added to the initial estimate. Therefore you will receive a separate email including the additional components to your Wire Harness Estimate.


STEP 6) Review and Submit 

Wire Harness Estimate


Lastly, the Summary page allows you the opportunity to review your entries and make sure that everything looks accurate.

Additionally, once you are satisfied with your selection simply enter your name and email address. You may also enter a project number to help keep track of each Wire Harness Estimate.

Finally, enter the correct number for the captcha and hit SUBMIT. Finished!

Finally, you will receive your Wire Harness Estimate within seconds in your email box.

Let’s Connect

Thank you for reading our blog on “Instant Wire Harness Estimate: Your Step by Step Guide.”

For additional information on Wire Harness Manufacturing, please check out these posts:

Also, please connect with us on the Falconer Electronics Inc websiteFacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!

UL Standards

As we continue our series on New Product Development, a key component with the process includes obtaining certification at UL Standards. In the last post we discussed “The Importance of UL, CSA, and ETL Safety Certifications“. Earning UL listings offer your customers the peace of mind that your product tested and in addition, passed rigorous UL standards. Also, having gone through the process repeatedly for numerous products lends a valuable experience to our team. Therefore, gaining the knowledge and a full understanding of the expectations required for UL Standards allows us to help our customers with these challenges.

UL Certification Guidelines and Rules 

“UL Standards encompass UL’s extensive safety research and scientific expertise. With over a century of experience in the development of more than 1,500 Standards, UL is an accredited standards developer in the US and Canada. In addition to extending its global public safety mission, UL Standards partners with national standards bodies in countries around the world to build a safer, more sustainable world.”

Here is a helpful link to the UL Certification, especially for new product developers: “Specific Guidelines and Rules“.

Additionally below is a link to “A Guide to United States Electrical and Electronic Equipment Compliance Requirements”:

Furthermore, there  is a video on Accessing UL Standards Documents: UL Standards Certification Customer Library (SCCL):

List of UL Standards at Falconer Electronics 

If you are not experienced with UL Standards, the list below includes the UL Listings that Falconer Electronics obtained over the years for our products. Additionally, you can click on the UL Standards below: 

UL 1363

Portable Outlet Strip-

  • Indoor
  • Cord and plug
  • Movable
  • Less than 3 receptacles
  • Also, provides ground fault

UL 111

Hardwired Outlet strip

  • Multioutlet assembly
  • Raceway
  • Dry locations
  • Also strips without cords/  not permanently wired in

UL 5

Surface metal Raceways and fittings

  • Enclosed circuits operating at no more than 300 volts
  • Can either be metal or non-metal
  • This does not, however, include cover cable trays, wireways or nonmetallic raceways

UL 48

Electric Signs

  • Includes electric signs, art forms and outline lighting for use in accordance with the National Electrical Code, NFPA 70
  • Also, voltage is not a factor
  • Types of lighting included
    • Incandescent
    • Fluorescent
    • High-intensity discharge (HID)
    • Electric discharge tubing including neon tubing
    • Light-emitting diode (LED)
    • Skeleton neon tubing
    • Cold-cathode lamps
    • Also, electroluminescence
  • Furthermore, “Signs” included
    • Signs
    • Outline lighting
    • Art forms
    • Skeleton neon tubing.
    • Awning signs
    • Trailer-mounted signs
    • Electrically or mechanically animated signs
    • Signs supplied by photovoltaic systems in addition to other independent power sources
    • Changing message signs
    • Including scrolling
    • Flipper
    • Tri-view
    • Liquid crystal display (LCD)
    • Light-emitting diode (LED) type
    • Also, there are other electrically operated signs that are not necessarily illuminating.
  • Not included however
    • Illuminated clocks operating at 600 V or less; refer to the Standard for Household Electric Clocks, UL 826 or for commercial use clocks to the Standard for Time-Indicating and -Recording Appliances, UL 863;
    • In addition to, Exit signs; refer to the Standard for Emergency Lighting and Power Equipment, UL 924;
    • The trailer of a trailer mounted sign;
    • Luminaires mounted to function as outline lighting; refer to the Standard for Luminaires, UL 1598;
  • Additionally, Luminaires mounted within an Awning Sign; refer to Standard for Luminaires, UL 1598;
  • Signs that do not use electricity;
  • Luminaires intended for billboard illumination; refer to Standard for Luminaires, UL 1598;
  • Fiber optics or Fiber Optic Illuminators;
  • Also, Signs for use in hazardous (classified) locations as defined in the National Electrical Code, NFPA 70.

UL 183

Manufactured wiring systems includes:

  • Outdoor locations
  • Field-installed wiring assemblies using off-site manufactured subassemblies for branch circuits
  • Remote-control circuits
  • Signaling circuits
  • Also, communication circuits in areas that are accessible

Finally, thank you for reading this blog on UL Standards. Additionally, we will be continuing our series on New Product Development.

Let’s Connect 

Additionally, to learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!




Prototype! A well working Prototype!

To continue our series on New Product Development by building “Building a Better Mousetrap”, let’s explore creating a prototype.

When starting out with a brand new product, perfecting a working model is crucial. Yet, establishing a fully functioning prototype does not necessarily guarantee success. Building a sustainable business model is equally as important.

All Products are in the Prototype Stage

Here is an interesting thought to consider: Every product that exists is in the prototype stage. Just some prototypes have already hit the market. Even stayed on the market for an extended period of time. That is until a “Better Mousetrap” came along.

What are you talking about, you ask?

Here is an example to consider. Kodak film was in working prototype stage….for decades. Actually over a century. A massive success. Then digital photography came along and replaced it. The prototype of print film finally succumbed to a new technology, digital photography.

The brutal irony is Kodak invented digital photography in 1973.  By a 24 year old Kodak engineer named Steve Sasson. Kodak didn’t take the new innovation of digital photography serious though.

How could they? Digital photography would slaughter the golden calf. Destroy the cash cow. Or any other bovine reference you prefer. Millions upon millions of annual Kodak profits would be jeopardized had they embraced digital photography.

Fast forward, Kodak no longer rules the photography market. Especially shocking considering Kodak served on the Dow Jones Index over 70 years from 1930-2004. As a matter of fact, anyone under the age of 20 (out side of Rochester NY) has probably never even heard of Kodak.

How About Crackberry?

Another example of a prototype that hit the market with great success, then disappeared was Blackberry. Blackberry initially dominated the market with cutting edge smart phones. It was even compared to one of the highest addictive drugs on the planet being called the “Crackberry”. Customers could not put it down. Until Apple came along with a better prototype. A “better mousetrap”. The iPhone.

There are millions of examples of products that never make it to market. Kodak and Blackberry demonstrate sad examples of working products that once dominated an industry can disappear in a blink of the eye. Product development is a tough business.

Minimal Viable Product = Working Prototype

So what does that mean to an inspiring inventor? An overly confident entrepreneur who has an exciting new product? How can you ensure success?

Start with making sure your product works. Works extremely well. Create a solid working prototype.

As we discussed previously, establish an all-star team to guide you to success. Starting with finding a quality electrical engineer.

A prototype proves your idea and concept. It solidifies the viability of your product. Eric Reis in his blockbuster book, “The Lean Startup” discusses bringing the MVP to market. A Minimal Viable Product.

Before spending tens of thousands of dollars on a patent, make sure that your product works. More importantly, that consumers (outside of immediate friends and family) are willing to part with their hard earned money to pay you for this exciting new product.

Below is an outstanding video from Google on prototyping:

Thank you for reading our blog as we continue our series on new product development.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!


John Teel at Predictable Designs

WOW! After reading several fantastic blog posts from John Teel at Predictable Designs, we decided to share this extremely valuable information.

Especially for the individual or company that is plunging into designing and developing electronics for the first time.

We strongly recommend that you explore the Predictable Designs website. 

In particular, John’s blog posts deliver a wealth of helpful information.

Also, sign up for John’s email list. He provides a raw perspective on developing electronics hardware.

For example, you will want to read John Teel’s Ultimate Guide – How to Develop a New Electronic Hardware Product: click here.

As John describes, “Whether you’re an entrepreneur, maker, inventor, start-up, or small company this guide will help you understand the new product development process!”

This post goes into the down and dirty details of launching a new product. John certainly does not sugar coat anything. He does an amazing job providing helpful information and guidance with this daunting process.Predictable Designs

Avoid the 95% Product Fail Rate 

As we discussed in a previous blog post, of the 30,000 new products launched each year, 95% fail. Ouch!

How do you avoid falling into the dreaded 95%? What does it take to join the elite group of 5% successful product launches?

With his years of experience, John Teel explains the many reasons products fail with another incredibly helpful post: 13 Reasons Why Hardware Startups Fail (and How to Make Sure Yours Doesn’t)

Build More Than a Product – Build a Business 

In addition, John brings a strong business-minded approach. Not just with creating amazing products but he also focuses on the profitability of your project as well.

You are not just developing a product.  John explains that it is crucial that you build a company around the product. A sustainable and profitable entity.

Once again, John lays out another outstanding post to help you. This post looks long-term beyond the product itself. Check out his post, Want to Make Millions? Don’t Develop a Product – Do This Instead!

How to Cost Out Your Product Design 

Lastly, John offers a step by step process with costing out your new product development.

Particularly helpful if you are in the infant stages of developing a new product in electronics for the first time. 

John covers every detail. He thoroughly explains the process with his Essential Guide – The Cost to Develop, Scale, and Manufacture a New Electronic Hardware Product.

Here is a video where John goes into a case study explaining product development costs as well as expenses related to obtaining regulatory certification:

We hope you enjoyed this post on Predictable Designs. As a manufacturer of  Wire Harnesses, Ground Straps, and Commercial Power Strips, we find John’s information, tips and advice priceless.

Let’s connect

Finally, for more info on electronics manufacturing, please connect with us on Twitter and LinkedIn.

Electrical Engineer

Searching for an Electrical Engineer 

Last week we discussed “Building the Better Mouse Trap“. So let’s just say that you have a brilliant new product in mind. A solution that customers will love!

It’s now time to move forward with your exciting idea for developing a new product in electronics.

You know exactly how the product should work. This is going to completely disrupt the market.

You will be on Shark Tank soon pitching your new game changing product. You are going to make a fortune.

Electrical Engineer

Yet, one problem though. You lack an electrical engineering background.

Therefore, if you are not an Electrical Engineer, it would certainly help tremendously to connect with a worthy candidate. Especially an electrical engineer that you trust.

Where do you turn if you do not know an electrical engineer? Who are you going to call?

Do you hire a large firm? They may have significant resources but you find them really expensive.

Or would you prefer to find a small firm or even an individual consultant? Limited resources but possibly less expensive and more flexible.

You need someone that is experienced. Excited about your product. Trustworthy. Relentless. Deeply committed to your success.

Let’s explore several options to consider in your quest to find a high quality electrical engineer.

Volt Vision 

We are blessed to work closely with Steve French, LED specialist and President of electrical engineering firm Volt Vision. Steve has a dynamic background particularly working with LED lighting solutions.  It is a huge asset at Falconer Electronics having Steve as part of our team.

Steve is an expert in LED lighting and a fantastic musician as well. So his creative side combined with being an outstanding engineer makes a killer combination with LED lighting projects.

The Friends and Family Plan

Moving forward, if you do not have an existing relationship with an electrical engineer, start with your inner networking circle. Any friends, family, long lost relatives, college fraternity brothers or sorority sisters? Maybe someone from your soccer team 20 years ago? If not, let’s continue our search……..

Linking with an Electrical Engineer on LinkedIn 

Hopefully, you have a LinkedIn account. This is a great place to find professional connections. Especially in a specialized field such as an Electrical Engineer.

Just type “Electrical Engineer” or “Electrical Design Engineer” into the LinkedIn search box. You can search by:

  • People
  • Jobs
  • Content
  • Companies
  • Groups
  • Schools

LinkedIn is a powerful resource. For example, nearly 200,00 LinkedIn members belong to the LinkedIn Group Mechanical Design Engineers. Over 38,000 LinkedIn members have joined the Electrical Engineers Group.

Other Social Media 

If you find yourself still looking, jump on social media. Depending on the demographic or specialty that you are targeting, start with the platform that you are most active on:

Google Search 

Still no luck so far. You can turn to your trustworthy old friend, Google. If you just do a general search for “Electrical Engineer”, you are going to receive broad results. Having just conducted a search, it seems to be mainly job listings that turn up.

If you prefer someone local, type in your city in as well (Ex: Electrical Engineers in Boston).

Furthermore, you could type the specific type of engineer that you are searching. Ex: PCB engineer, energy systems, microelectronics, systems and controls, etc…

Local Business Networking Groups 

Do you belong to a local business networking group?

Chamber of Commerce

Local Networking Groups (Ex: BNI)

Small Business Development Center – The Small Business Development Center is also an excellent resource that can help out with your search.

Online Professional Freelance Websites

Lastly, there are numerous professional matchmaking websites to consider. All of these sites below offer connections to a wide variety of electrical engineers:

Electrical Engineer


Wrapping it Up 

Well, we wish you MASSIVE SUCCESS with your exciting new product.

Thank you for taking the time to read our blog on searching for an Electrical Engineer. Also check out our continued blog series on Developing a New Product in Electronics.

If you need information on a Wire Harness with your new product, click here for tips on outsourcing.

Let’s Connect

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

For more info on electronics manufacturing, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wire Harness Manufacturing

Wire Harness Manufacturing is our foundation. It’s in our blood. Dating all the way back to 1985. The Team at Falconer Electronics Inc. (FEI) takes tremendous pride in manufacturing amazing products for our customers. In addition, as a Custom Wire Harness Manufacturer, assembling and delivering superior products is our mission. Actually, we are wire harness geeks so we call it our Crusade.

Wire Harness Manufacturing: Steps for Success

  1. Superior Quality
  2. Maintaining Impeccable Customer Scorecards
  3. Fast Turnaround Times
  4. Competitive Prices
  5. Highly Skilled and Seasoned Staff
  6. FREE Instant Estimates (click here)
  7. High Productivity
  8. Agility and Flexibility
  9. Company Culture Dedicated to Customer Satisfaction
  10. Lastly, a Commitment to Safety

The Secret to Success

Our wire harness assemblies can be found all over the country. Especially in the following places:

  • As you walk around Walmart or Lowe’s, you will walk past our wire harnesses. They can be found in the commercial power strips and electrical retail fixture displays.
  • If you drove past a semi-truck today (or if one went flying past you). Our wires may have been waving to you.
  • Our wires are in some dentist offices (not during a root canal – we refuse to contribute to that type of pain).
  • If you rode on a train today. Our wires may also have been riding along with you.
  • Another example includes our proprietary line of magnetic work lights and trouble lights
  • ATM Machines
  • Heating Systems
  • Handicap Accessible Transport Vehicles
  • Electrical Signage at retail cash registers as well as self check-out kiosks 
  • Along with Much More…

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Helpful Guide of Wire Harness Manufacturing Terms, Tools and Tips 

Are you new to the Wire Harness process? Our team created a helpful guide below.

The Wire Harness Manufacturing Guide includes:

  • Wire Harness Terms
  • Tools
  • Tips of the Trade

Additionally, the list below includes a number of Wire Harness Manufacturing Terms and definitions.

Wire Harness Manufacturing IPC/WHMA-A-620 Standard 

All of the Wire Harness Manufacturing Terms below are from the IPC/WHMA-A-620. This serves as an industry standard. Therefore, providing criteria for commonly used wire harness assemblies.  Consequently, the standard sets a “collection of visual Quality Acceptability Requirements for Cable, Wire and Harness Assemblies.”

To learn more about the IPC/WHMA-A-620, click here.

Wire Harness Manufacturing Terms and Definitions

American Wire Gage (AWG)

A standard system for designating wire diameter. Primarily used in the U.S.


The raised portion at the front and/or back of the wire barrel crimp that provides a gradual entrance and exit for the wire strands without causing damage.


Wire Strands that have separated from the normal lay of the wire.


Woven bare metallic or tinned copper wire used as shielding for wires and cables and as ground wire for batteries or heavy industrial equipment. Also, a woven fibrous protective outer covering over a conductor or cable.


A group of individually insulated conductors in the twisted or parallel configuration under a common sheath.

Cable Assembly

A cable with plugs or connectors attached.


An uninsulated wire or the conductor of an insulated wire suitable for carrying electrical current.


A tube in which insulated wires and cables are passed.


A device used to physically and electrically join two or more conductors.


The conducting part of a connector that acts with another such part to complete or break a circuit.


A continuous path for the flow of current in an electrical circuit.


Final configuration of a terminal barrel formed by the compression of terminal barrel and wire.

Crimp Height

The measurement of the overall wire barrel height after crimping the terminal.


Total current is the combination of resistive and capacitive currents. Resistive current is present in both AC and DC DWV tests. Additionally, the capacitive current is present only with fluctuations in applied voltage (Ex: AC testing).


Any insulating medium that intervenes between two conductors.

Double Crimp

The process of two or more mechanical crimping operations on the same location in a single terminal.


A short tube. Used to make solderless connections to shielded or coaxial cable. Also, a terminal crimped onto the stranded wire to allow insertion into terminal blocks.


A rubber seal used on the cable side of multiple contact connector to seal the connector against moisture, dirt or air.


A group of wire and cables, usually made with breakouts. Furthermore, with a rubber or plastic sheath tie them together. A harness also provides interconnection of an electric circuit.


A material that offers high electrical resistance making it suitable for covering components, terminals, and wires. This material also helps to prevent the possible future contact of adjacent conductors and a resulting short circuit.

Insulation Crimp

Area of a terminal, splice or contact formed around the insulation of the wire.


An outer covering, usually nonmetallic, mainly used for protection against the environment.


A device attached to certain connectors that permit uncoupling and separation of connector halves by a pull on a wire or cable.

Multiple-Conductor Cable

A combination of two or more conductors cabled together and insulated from one another and from sheath or armor where used.


A mechanical arrangement of inserts and/or shell configuration that prohibits the mating of mismatched plugs and receptacles.

RF Connector

Connector used for connecting or terminating coaxial cable.

Ribbon Cable

A flat cable of individually insulated conductors lying parallel and held together by means of adhesive film laminate.

Strain Relief 

A technique or item which reduces the transmission of mechanical stresses to the conductor termination.

Stress Relief

A predetermined amount of slack to relieve tension in component or lead wires.


A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another conductor, etc., to establish an electrical connection. Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged.


A tube of extruded non-supported plastic or metallic material.


Slender rod or filament of drawn metal.

Wire Diameter

The overall conductor plus insulation thickness.

Types of Wire Terminals 

The definition of a terminal is:

A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection.

Wire Terminals come in many different shapes and sizes. This is due to the size of the wire and screw. Also, there are several types of terminals.

Wire Harness Manufacturing Terminals Include:

  • Ring
  • Spade
  • Hook
  • Quick-disconnect
  • Bullet
  • Butt terminals
  • Flagged

Wire terminals are available in insulated and non-insulated. The insulation provides a protective cover. Therefore, serving as a non-conductor. Furthermore, the type of project that is being done will determine if you need insulated or non-insulated terminals.

The insulation spares the wire from water and moisture as well. Also, it protects against extreme heat or cold. Wire insulation is typically available in vinyl, nylon and heat shrink.  Non-insulated terminals provide much more economic value with its low cost. Also, they are commonly used when extra protection is unnecessary.

When purchasing various Types of Wire Terminals, make sure that your purchase meets industry standards as well as project requirements.

Wire Terminals

Ring Terminals

Types of Wire Insulation

A ring terminal is a round-ended terminal that easily allows a screw or stud to be attached. Ring terminals also called ring connectors, come in various sizes. It is crucial that the ring terminal is compatible with the wire gauge and stud size. Ring Terminals are either crimped or soldered to the wire. Available in insulated or non-insulated.


Spade Terminals

Spade Terminals are also called spade connectors or fork terminals due to the shape of the terminal. A spade terminal is available in various sizes depending on the gauge of the wire and stud size. Additionally, the open-ended spade terminal is convenient to use allowing easy attachment or removal from the screw. Especially for wire harness projects that are tight on space for installation. They are also available in insulated or non-insulated.


Hook Terminals

Similar to the Spade Terminal, Hook Terminals are convenient to use with an open end (imagine a tiny version of Captain Hook). These terminals are produced as insulated or non-insulated. Hook Terminals offer a simplistic yet durable connection for a variety of projects.



Quick-Disconnect Terminals

A quick-disconnect terminal provides convenient and reliable usage while also offering an easy connect and disconnect between two wires. They are commonly found in auto, industrial and consumer products. Products can be insulated or non-insulated. Quick-Disconnect Terminals additionally deliver a stable and durable connection.


Bullet Terminals

Types of Wire Terminals

Bullet Terminals (also called bullet terminals) make an easy, reliable and secure connection. It is simple to disconnect as well. Bullet terminals also connect with the male and open-ended round female connectors creating a high-quality connection. Therefore, the connection with bullet terminals helps prevent corrosion and other potentially harmful materials from entering a wire harness.


Butt Terminals

A Butt Terminal connects or terminates single or multiple wires. Butt Terminals help prevent abrasion and cutting. Additionally, this extra protection helps keep out moisture, corrosion, and other negative elements. Butt Terminals serve as a simple solution to extend wires due to the ability to mate and connect wires. Simply install each wire on the open end of the connector, then crimp both ends of the terminal to secure the connection.


Flagged Terminals 

Flag Terminals also called flag connectors to offer a convenient and secure connection. Flag terminals work well in tight spaces as well as when a quick-disconnect is too large. Provides a quick and easy connection and disconnect. Also available in insulated and non-insulated.


Wire Insulation

Wires can be found… seems like… everywhere. Any electrical product that demands a current flowing will typically require a wire (or cable). Even when you hear something is “wireless”. In this instance wires power the device sending a signal. Electricity traveling through wires bring each of us tremendous joy and pleasure.

Examples of electronics containing wires:

  • Computers
  • Internet routers
  • Also, music players (MP3 and iPods)
  • Communication devices (Cell Phones)
  • Vehicles
  • Appliances

Actually, can you imagine surviving a single day without electricity? Well, in the early stages, electricity did not travel so safely through wires. Thankfully electricity travels safe and sound through wires protected with wire insulation.

Wire Harness Manufacturing

The explosive growth of electrical products well over a century ago drastically increased the use of wires carrying electricity. Unfortunately, uncovered or exposed wires were responsible for dangerous situations.

Furthermore, exposed wires led to electrical shocks or fire. However, the addition of a non-conductive cover was a brilliant move to protect and strengthen wires. The application of Wire Insulation protects wires greatly reducing potential hazards and threats.

You can take a look at wire insulation in the 19th century.

Check out this cool video on porcelain insulators. Thanks to Thomas Edison Tech Center.

 Wire Insulation Evolution

Due to increasing demand, electrical products require a solution to protect wires. The solution is affordable and efficient. Also, with the early growth in popularity, wire harness assembly has become necessary. It is much more efficient in harnessing loose wires. This is opposed to a “free for all”. Especially for electrical consumer goods and the auto industry. Both of which have exploded since the early 20th century.

Insulation serves as a non-conductor. The Insulation also separates and protects wires within a wire harness assembly. Especially since it is a nasty world out there with many detrimental elements that can cause harm to non-insulted wires.

To save the day, an insulated jacket protects each wire from the elements keeping the wire cozy and safe. Like insulated terminals, wire insulation also protects from moisture and extreme temperatures.

Thankfully wire insulation today is much more efficient. It is also, effective and affordable.  For example, thermoplastic high heat-resistant nylon coated wire (THHN wire) is low in cost. It is also lightweight. Due to these factors, it is an extremely popular wire insulation option.

Now that you know all about terminals and wires you need to know how they come together to create a wire harness.

Crimping Tools

We have over 30 years of wire harness manufacturing experience. Also, we here at Falconer Electronics have accumulated an impressive arsenal of crimping tools. When crimping wires and cables for our customers we have to utilize the proper tools. These allow our team to execute jobs with accuracy and efficiency. As well as, in a safe manner.

Many projects require crimping wires by hand. When producing wire assemblies for prototypes and small volume runs, handheld crimping tools sure come in…well… handy.

It is extremely important to look over the entire assembly when selecting the proper tool. For example, a basic pliers-style crimp tool can fit various wires, connectors, and terminals. Also, matching the right size tool is imperative when terminating wires.

A great brand is Molex. They are a global leader in the manufacturing of high-quality electrical tools. They are also a leader in components and other equipment. Falconer Electronics hax relied on Molex for many years. We trust their products.

The team at Molex declares they solve challenges “through our collaborative process, we take a multi-dimensional approach that brings together engineers, product designers, and manufacturers to ensure the design cycle is smooth and seamless.”

Below is one of the “Bad Boys” from Molex that our team loves to use when tackling tough projects:

Pneumatic Crimping Tool

Not interested in crimping wires by hand? Or do you have a large amount to crimp? No problem. Pneumatic crimping tools are extremely beneficial and efficient. Additionally, a pneumatic tool allows you to work hands-free due to air power. These tools are also fast and accurate. All qualities that will drastically increase your production.

We recently welcomed a new addition to our team. The Pneumatic Crimping Press pictured below. The “Plug’n Play” Pneumatic Press looks fierce, doesn’t it? It is ready and raring to CRIMP!! Especially ideal for wires requiring interchangeable crimping dies:

Tips for Successful Wire Harness Manufacturing 

  • The crimp does not break the insulation.
  • Also, the crimp fully wraps around and supports insulation (also cannot expose an opening greater than 45 degrees).
  • Insulation does not have puncturing to the point where tabs penetrate the wires.
  • Crimp tabs are in contact with the top of the insulation.
  • Insulation is flush with the crimped wire.
  • Additionally, identifying damaged insulation that reveals wires.
  • The wire, connector, assembly process, as well as insulation, are all compatible.

Wire Harness Manufacturing

Wire Harness Manufacturing: Crimping Wires Do’s & Don’ts

The IPC/WHMA-A-620  standard provides the necessary guidance on crimping wires. Consequently, this standard shows what is acceptable along with what is considered defective. Here are a few examples of Do’s and Don’ts:


  • Insulation crimp tabs fully wrap and support insulation
  • Additionally, the insulation fully enters and extends past the insulation crimp tabs
  • Wires must be in solid working condition – also cannot have scrapes, nicks, severing or other damages
  • The connector retains the wires
  • Center the crimp indent
  • Insulation crimp must provide a minimum side report of 180 degrees


  • Wires should not have deformities- Flattening untwisting, buckling, or kinking
  • Insulation should not show any signs of pinching, pulling, fraying, discoloration, or charring
  • Also, the insulation crimp needs to fully support and wrap insulation without causing any damage or breaking the insulation
  • No broken insulation- This can expose wires causing safety issues and potential hazards
  • Wire not secured by crimp
  • Contact has visible cracks and fractures
  • Also, no Birdcaging – Wire Separation

These are just a handful of the requirements.

To learn more about the Wire Harness Manufacturer’s Association and A-620 Standards, please click here.

Wire Harness Manufacturing Quality Control  

Wire Harness Quality Control is paramount at Falconer Electronics. We perform testing on cables and wire harness assemblies for every order. Therefore, quality control strongly impacts the bottom line with the wire harness assembly process. Also, our well-guided wire harness quality control and a solid test system prevents unnecessary errors, stress and lost profits.

High accuracy during the assembly process is the key to maintaining competitive pricing and reliability. We take every step to ensure accuracy at the time of assembling and producing the wires. Instituting a strict wire harness quality control system during production brings significant benefits to our customers.

Wire Harness Manufacturing Testing Check List

Safety First! Wire Harness Testing requires extreme caution. This is due to it involving live wires. Unfortunately, electric shock and burns can turn a great day into a really bad day quickly. It is mandatory to use personal protective equipment on the job such as safety glasses when testing a wire assembly.

When performing Wire Harness Testing, our quality control department strictly follows the IPC/WHMA-A-620 Standard. Most importantly, this standard is a collection of visual Quality Acceptability Requirements for Cable as well as Wire and Harness Assemblies.

Wire Harness Manufacturing Checklist for Testing Wires:

  1. Accurate Labeling
  2. Check for Damaged Insulation or Defective Wires
  3. Continuity
  4. Correct Wire Gauge
  5. Also, Check for Proper Crimps
  6. Free of Moisture and Corrosion
  7. Optimum Wire Placement Within Connectors
  8. Pull Test
  9. Test for Broken Wires
  10. Finally, Test for Shorts

Deming Values for Continual Improvement

Going old school, we are also big fans of 20th-century management guru Dr. Deming. Dr. W. Edwards Deming created 14 points for management with a quest for continual improvement. Especially since Dr. Deming is credited with being the master of quality improvement. Particularly with his work in Japan during the 1950’s.

The Deming Institute continues the incredible legacy of Dr. Deming.

Furthermore, one of the core values at the Deming Institute states:

We are dedicated to the Deming philosophy and the belief that working together, with humility, we can make a difference in the quality of life for everyone.

This is a truly inspiring message!

According to Dr. Deming, implementing the 14 points is a philosophical way of conducting business with an unwavering quest for continual improvement. In addition, new tactics and behaviors become habits. Furthermore, those habits eventually form into the core beliefs and culture of a company.

In particular, two interesting points from Dr. Deming’s 14 points that help drive our wire harness quality control:

1. Create constancy of purpose toward improvement of product and service, with the aim to become competitive and to stay in business, and as a result to provide jobs.

5. Improve constantly and forever the system of production and service, to improve quality and productivity, and thus constantly decrease costs.

Consequences when continual improvement and quality are NOT the top priority:

  • High defect rates
  • Underutilized equipment
  • Poor productivity
  • Poor inventory management
  • Safety concerns
  • Finally, low morale with employees

Dr. W. Edwards Deming

Wrapping it Up 

In conclusion, at Falconer Electronics, Wire Harness Manufacturing runs through our veins. Consequently, having built literally millions of Wire Harnesses over the past 30+ years. Actually many of our employees say they could build a wire harness in their sleep. (Is that why they started bringing their pillows to work?)

However, on a serious note, Wire Harness Manufacturing drives our business. Furthermore, delivering consistent and high-quality Wire Harness Assemblies contributes greatly to our successful long-term customer relationships dating back to 1985.

Thank you for reading our post on Wire Harness Manufacturing Terms, Tools, and Tips of the Trade.

Also, for more information on Wire Harness Manufacturing, click here:

For additional information click on the links below:

Lastly, connect on Facebook, Twitter, and LinkedIn for more electronic info.



Building a Better Mousetrap That is Profitable 

“If You Build a Better Mousetrap, the world will beat a path to your door.” American philosopher, Ralph Waldo Emerson is credited with that famous line from the nineteenth century.

Better Mousetrap

However, as legend has it, he never said those exact words. Ralph Waldo Emerson actually stated the following:

“If a man has good corn or wood, or boards, or pigs, to sell, or can make better chairs or knives, crucibles or church organs, than anybody else, you will find a broad hard-beaten road to his house, though it be in the woods.”

“Build a Better Mousetrap” just sounds catchier and flows easier.

Anyway, as the point remains, build a better product above the competition and customers will line up. Profits will pour in. If it were only that easy though.

Building a better mousetrap is a massive accomplishment. Creating a sustainable and profitable business model is a whole other story.

Side note: If you enjoy reading inspirational books and want to go “old school”, check out Ralph Waldo Emerson’s “We Are the Builders of Our Fortunes: Success through Self-Reliance.” Especially if you need a motivational boost with your new product. We strongly recommend it.

95% Fail or 5% Success

Creating and inventing a new product is tough. The process is certainly not for the weary. According to Harvard Business Professor Clayton Christensen, 30,000 new products are launched each year. Of those, 95% of new products fail! That is a crazy statistic.

You may actually face better odds of survival going over Niagara Falls than successfully establishing a new product.

With such a high fail rate, why do inventors and innovators even attempt to fall in the successful 5%?

Ego? Delusion? Determination? Fame and fortune?

Typically everyone thinks they have created the “better mousetrap”. Surely, no one goes into new product development expecting to join the 95% failure club.

To be successful, you need to put the odds in your favor by exhausting due diligence. Gathering every resource in your corner to achieve success.

Persistence and Determination  

Over the years, we have worked closely with a wide variety of companies that have internally engineered new electrical products (better mousetraps).

Areas that our team focuses on include the following: Wire Harness Assemblies. Ground Straps. Commercial Power Strips. Printed Circuit Boards.

We have made lots and lots of prototypes for customers over the years. Throughout our experience, a common phrase heard from engineers, “Going back to the drawing board”.

Yet, this just means that the person or company continues striving for perfection. Making the PERFECT mousetrap.

From our experience, persistence and sheer determination are two ingredients required to launch a successful product.

We thought you might enjoy this quick video explaining the “Build a Better Mousetrap” concept:

Finally, as you strive to bring your “better mousetrap” to market, surround yourself with experts that contribute greatly to your cause. Seasoned veterans who have been there before. Trained guides familiar with the challenging terrain. Individuals committed to your success.

Thank you for reading our post on “Building a Better Mousetrap”. This blog kicks off our series on developing a new product in electronics. Please check back each week for more info.

Let’s Connect

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

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Ribbon Cables

What are Ribbon Cables

Ribbon Cables

Ribbon Cables consist of multiple wires attached to each other in the form of a flexible ribbon. Due to their flexibility Ribbon Cables have many different functions. Also, they are a vital part of multiple electronics.  Another term for these cables is “flat cables”. This is a literal description of their appearance.

Structurally speaking the individual conductors form a ribbon by the addition of an insulating material. This material is usually PVC. However, Teflon is another material that can insulate the conductors.

Knowledge is Power

Have you ever gone to a mechanic with a vehicle issue? It is helpful to be able to describe your problem. Better yet if you know exactly the problem it will be quicker and easier for the mechanic to fix. People tend to want to laugh when they see a customer bring a car in for an issue and you hear them trying to make the grinding noise that their tire is making. However, if a mechanic can identify that sound they are more likely to go straight to the source of the noise.

How often does anyone think about the components of their everyday electronics? The same thing can happen with electronics. The more knowledge of components that a consumer has the better equipt they are to describe an issue. There are so many electronics that contain ribbon cables.  Electronics we use every day like computers, phones, and televisions contain Ribbon Cables. The more that is known about these cables the more likely it is that any issues that occur will be found.

Where You Can Find Ribbon Cables

Ribbon Cables are often chosen for projects due to their fixed-wire position and the ease of installation. Their fixed wire positions ensure that there will be no crossed wires or shortages. Also, there is the added perk of each individual wire having their own insulation.

Due to their flexible nature and their wire positions, Ribbon Cables are commonly known for their part in computers. Usually found in computer hard drives and CD drives. These cables are also parts of many consumer electronics products, test and measurement equipment, automated termination equipment, robotics, and even some medical equipment.

Connect with Us

To Get a Personalized Estimate for Ribbon Cables Visit Our Wire Harness Estimator.

Follow us on our Facebook page!

Also, for more info on electronics manufacturing, please connect with us on TwitterGoogle+, and LinkedIn.

Custom Light Switch Manufacturing 

Companies of Light Switch Manufacturing and Lighting Control seek our expertise in soldering. Falconer Electronics can provide either a complete turnkey comprehensive solution as well as a customized plan for your project.

Our soldering team brings over 100 years of combined experience. It is essential to partner with a seasoned custom manufacturer that you can trust.

Lighted Light Switch Manufacturing 

Properly conducted materials planning and procurement enable efficient production. However, many facilities do not give this manufacturing requirement the attention it needs. Mishandled inventory causes inefficient production leading to unnecessarily increased costs. However, Falconer Electronics provides achieved proficiency with this manufacturing complexity due to their many years of production expertise.

Fast turnaround is the end result of proficient planning while controlling costs is absolutely essential. Due to constant business challenges, increasing your efficiency and profitability is our highest priority.

Since manufacturing is the pre-production benchmark that guarantees post-production satisfaction this benchmark lies in the building of quality prototypes. Falconer Electronics produces quantity assemblies for a variety of clients from residential electrical hardware to large retail store display electromechanical assemblies.

This product example includes components that are used in residential electrical applications for lighted on/off wall switches.

Light Switch Manufacturing

Lighted Light Switch  

Quality Control

Another benefit at FEI, quality control follows every step through the production process. This ensures that superior product is manufactured every time. Wire Harness AssembliesGround Straps and Commercial Power Strips are areas of expertise at FEI.

Also, Falconer Electronics often assembles products that meet stringent UL specifications. Falconer Electronics can assist in obtaining the challenging quality assurance process on behalf of their customers. This includes handling the entire process with CSA, ETL or UL.

The mission of Falconer Electronics is to provide customers with assemblies built to their unique specifications. Resulting in the most economical cost while maintaining the highest quality workmanship and on-time delivery. Therefore, this is why at Falconer Electronics, “Made in the USA” means high quality and customer satisfaction.

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Custom Cable Harness Estimator Picture - Custom Wire Harness Estimator Ribbon

The History of Ribbon Cables


The Early Years

The Ribbon Cable was first discovered in 1956 by Cicoil Corporation. Its original design was to be flat to fit into computers. They were to replace the large and inflexible cables. Engineers were able to figure out a way to use liquid silicone rubber to mold a very thin flat cable. They also contain multiple conductors of the same size, controlling the spacing of each internal copper wire. The Flat Cable allowed companies like IBM, Sperry/Univac, Honeywell, GE and NCR to replace bulky, stiff round cables with sleek, flexible ribbon cables.

Custom Cable Harness Estimator Picture - Custom Wire Harness Estimator Ribbon

In addition, in the 1960’s NASA was in need of a mission-critical, lightweight cable. Cicoil’s Cables met all of the rigorous requirements for a Space Flight Cable. As a result, the cable harness helped America put a man on the Moon. As a result, the lightweight Ribbon cables were integral to the first American Orbit of the Earth, first Space Walk in 1965, and the Lunar Landing in 1969. In addition in 1998, a new extrusion process allowed manufacturers to continuously produce lengths of flat cable.


Today, Ribbon Cable comes in all different shapes, sizes, and colors. They are also in a huge range of applications. From high-speed computer connections with coaxial cable to rainbow cable. Many different methods and materials go into simplifying and reduce the cost of these cables. The standardizing of the design and spacing of the wires and the thickness of the insulation. They could also be easily terminated through the use of insulation displacement connectors. Finally, the simplicity of the cables, their low profile, and low cost due to standardization allows ribbon cables to be in computers, printers, and many electronic devices.

For more information on where to find these colorful cables and their uses, Check out next weeks blog!

Connect with Us

To Get a Personalized Estimate for Ribbon Cables Visit Our Wire Harness Estimator

Follow us on our Facebook page!

Also, for more info on electronics manufacturing, please connect with us on TwitterGoogle+, and LinkedIn.


Wire Harness Manufacturer

Welcome to today’s discussion on outsourcing your wire harness assembly to a Wire Harness Manufacturer. In particular, outsourcing your wire harness assemblies for a critical project. Finding yourself in the beginning stages of searching for a new Wire Harness Manufacturer to partner with presents several  challenges. Let’s go on a buyer’s journey to help assist you with the selection process. 

Why Outsource to a Wire Harness Manufacturer? 

First, outsourcing to a Wire Harness Manufacturer gets you in the game immediately without adding significant overhead and fixed costs.

Establishing the wire harness assembly process as a variable expense lends tremendous value and flexibility to your growth and profitability. This allows you to eliminate the financial risks of taking on the exorbitant investment required to build your own wire harness department.

In order to create your own wire harness assembly department, you would need a designated area in your facility. That is if you actually have the space to conduct these tasks.

Your next step requires purchasing all of the proper equipment, machinery, and crimping tools. However, this investment adds up quickly. Even into the tens or hundreds of thousands of dollars.

Having a properly trained staff in place is another major investment of time and resources. For example, crimping wires safely and accurately requires extensive experience and a specialized skill.Wire Harness Manufacturer

Top 10 Tips for Selecting a Wire Harness Manufacturer

So if this sounds unrealistic and overwhelming, you need to consider what steps are necessary to find a Wire Harness Manufacturer that will serve as a trusted partner.

You now might be asking yourself:

  • Where do I begin my search?
  • What type of questions should I ask when interviewing a Wire Harness Manufacturer?
  • How can I determine that this Wire Harness Manufacturer is a solid fit with our company culture and goals?
  • Is this a trustworthy candidate?

Well, we have you covered. Below is a 10 step process to consider when outsourcing to a Wire Harness Manufacturer.


Is it Time to Outsource to a Wire Harness Manufacturer? 

“Should we begin outsourcing our Wire Harness Assemblies to a Wire Harness Manufacturer?”

This is a common question our new customers typically ask themselves before reaching out to us.

Many times in life, if the question crosses your mind, then odds are it is time to act.

For example, is it time to discard those old ratty sneakers that offend everyone around you? Most likely, it is time to let go.

Do you eat the leftover seafood from Monday night…on Saturday? Probably not a good idea.

If you have been asking yourself if it is time to outsource to a Wire Harness Manufacturer, odds are the time has arrived. At the very least, it certainly doesn’t hurt to investigate further.

Start by identifying what event occurred or how this question arrived. Understanding when, how and why your internal Wire Harness Assembly Process became a burden is an important step.

What hold ups, hang ups, drag downs, hiccups, throw ups, headaches, heartaches, belly aches, or pain in the “you know what” occurred? Think about the moment where you said to yourself, “there must be a better way”.


Reasons to Start Looking  

Serving as a Wire Harness Manufacturer for over 30 years, we have found several scenarios where a customer approaches us for the first time. Typically the customer contacts us with excitement (or out of frustration) when they are Selecting a Wire Harness Manufacturer.

Let’s role play. Below are a few scenarios where a new customer finds themselves seeking a new Wire Harness Manufacturer…….

Scenario #1) New Product Design and Prototypes

Congratulations! You have just completed a brand new electrical product design. You and your team (or maybe you are a team of one) just exhausted weeks and even months designing your new product that is going to be a home run! Now what? You need a completed prototype. Also, an estimate to see if your new design can be produced at a competitive price.

For example (and a shameless plug), you can go to the Falconer Electronics Wire Harness Estimator for an estimate on your prototype. You will find the Wire Harness Estimator easy to use and works extremely fast. A quick estimate allows you to determine the potential cost and competitiveness of your new product. New customers love it.

Another concern with creating a prototype on your own includes the prohibitive costs. Purchasing the necessary quantities to begin the process can be cumbersome and not cost effective. A Wire Harness Manufacturer has the tools, equipment, staff, and infrastructure in place to create a prototype quickly and affordable.

Scenario #2) Jumping Into Electronics 

You are in the purchasing department of a company expanding into electrical products for the first time. Management has challenged you to seek out and find a Wire Harness Manufacturer that best demonstrates the ability to tackle this project.

Let’s say a mid-sized manufacturer is expanding into electrical wiring.  Two examples that fit this example. We recently began working with two separate companies:

1) One that specializes in handicap accessible transportation

2) An ATM manufacturer

They each produced a new proprietary product line requiring wire harnesses and printed circuit boards. It was a significant savings for each company to outsource the wire harness assembly process and printed circuit boards rather than to attempt to conquer the project themselves.

Scenario #3) Vendor Divorce 

Unfortunately, you and your current Wire Harness Manufacturer are no longer compatible. Who changed? It is like a marriage deteriorating quickly where “living like this” is no longer an option. Either quality has deteriorated, deadlines are no longer met, or prices continue to increase.

Whatever the case may be, it is time for a change.  Losing a customer is deeply disappointing and discouraging. Our team works relentlessly to maintain long-lasting and monogamous marriages with our customers. We also enjoy catching new customers on the rebound.

Scenario #4) In-House No Longer Working Out 

Your company no longer finds it efficient or profitable to produce wire harness assemblies in-house. The task falls into your lap to find a highly qualified Wire Harness Manufacturer. Selecting a company that you trust is essential!

This recently happened to a large customer. They found it much more cost-effective and profitable to outsource their entire line of wire harness assemblies by partnering with our staff. Our team went on full throttle to make this a smooth transition.

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Perform an Internal SWOT 

The next step, start with a SWOT on your internal Wire Harness Assembly process. What are the company strengths, weaknesses, opportunities, and threats? Especially if you are just starting up.  This step is critical to help determine financial risks.

Do the same procedure and create a SWOT if you were to outsource to a Wire Harness Manufacturer.

The next question becomes, “Who can solve this problem so we can focus on our core business”?

A key to building a successful business is partnering with experts in a given field. Successful companies exist by solving a problem. Solving a problem requires developing an area of expertise. A proficiency that stands above the competition.

Partnering with Seasoned Professionals 

You need to partner with a Wire Harness Manufacturer that thrives and works relentlessly to gain a competitive advantage. Also, one that creates economies of scale for you. Most importantly, a solution so valuable that it just doesn’t make sense to perform these tasks on your own anymore.

As a business owner or manager, you hire professionals to strengthen your business and protect your assets. This list includes hiring an accountant, attorney, or insurance broker who have invested the time and energy to educate themselves respectively on business law, tax codes or proper insurance policies. Especially since you rely heavily on these individuals to help you make critical business decisions. Surrounding yourself with highly trained and qualified professionals has the potential to pay huge dividends.

Outsourcing certain tasks within the manufacturing process offer similar benefits. Partnering up with a Wire Harness Manufacturer that maintains an all-star team creates a winning formula. This allows you to maximize profits while minimizing risks.


Where to Search for a New Wire Harness Manufacturer?

Once you determine that partnering with a New Wire Harness Manufacturer would be extremely beneficial for your company, now the fun begins.

Unless you already have a candidate in mind, most likely you will kick-start the search process by relying on connections within your network. A great place to start includes the list below:

  1. Vendors
  2. Suppliers
  3. Customers
  4. Chamber of Commerce
  5. Trade Associations
  6. Other local connections and business organizations

If you lack successful connections going this route, no fear. Call on your dear friend Google. Conducting a few Google searches will provide an array of companies that serve as a Wire Harness Manufacturer.

Is geography a critical factor? Not necessarily. Let’s say you were looking for a supplier of wooden pallets. You definitely need somebody extremely close. Otherwise, shipping costs would be brutal and cost prohibitive.

With a Wire Harness Assembly, shipping costs are typically not prohibitive and detrimental. Partnering with the right company in another part of the country can still be an effective and profitable relationship.

For example, we have customers throughout the entire U.S. We consistently ship to the west coast and Mexico as well. Shipping costs are particularly a non-factor compared to the quality of workmanship and consistently hitting tight deadlines.

Once you have discovered a worthy prospect, begin conducting company research and due diligence to see if this Wire Harness Manufacturer is a good fit for you.

Wire Harness Manufacturer


Due Diligence When Searching for a New Wire Harness Manufacturer

What can you determine from their online presence? 

Check Out the Company Website:

  1. First, explore the company website. Does the website represent the company as a partner that you can trust?
  2. Does the company reveal itself having the staff, tools, resources, and ability to tackle your project?
  3. Do they serve your industry?
  4. Do they have the experience and expertise to take on your project?
  5. Are company capabilities listed?

Check out their Social Media:

  1. Is the company active on social media with communicating their culture?
  2. Does it fit with yours?
  3. Does the company provide helpful tips?
  4. Communicate the company mission? Does the mission fit with yours?
  5. Can you easily submit a drawing of your wire harness assembly?
  6. When you contact them, do you receive a quick response?

Below includes a few additional questions to consider asking the Wire Harness Manufacturer:

  1. Types of customers they serve?
  2. What industry does the company target?
  3. Do they understand your needs?
  4. Do they have the flexibility to speed up during your busier times?
  5. Can they adjust to varying seasonal demands?
  6. Do you feel a chemistry and kindred spirit with this company?

Questions Regarding Vendor Relationships:

  1. Do they have outstanding vendor relationships?
  2. Do they have purchasing power?
  3. Are they willing to negotiate and fight for the lowest cost on products for you?
  4. Do they have strong cash flow and pay their bills on time so there are no delays in purchasing your product?

We will dig much deeper into questions to consider for your Wire Harness Manufacturer search, with #6 and & #7.


Asking Challenging Questions Captures Valuable and Critical Information 

At this stage, you have narrowed the field down. To either a single or hopefully only a few Wire Harness Manufacturer candidates. Now is the time to begin the interview process. Asking tough interview questions will help lead you to the valued partner that you desire.

This partnership will take your business to the next level. At least, that is the goal.


Being overly prepared and asking the right questions can save you a great deal of grief down the road. Hastily jumping into a new relationship with a custom manufacturer that turns sour can be devastating and difficult to recover. Depending on the severity. The divorce can get nasty and costly.

Having a list of tough questions prepared brings tremendous value to the process.

50 Questions When Interviewing a Wire Harness Manufacturer

To help discover if you are compatible with a Wire Harness Manufacturer that you are interviewing, below are a list of helpful questions to consider:

Round I: 

  1. What industries do you serve?
  2. Please describe your ideal customer?
  3. What has been your greatest victory in your business career or at your company?
  4. Biggest letdown or setback and how did you resolve?
  5. Could you share exciting changes taking place in your business?
  6. What are you absolutely best at?
  7. What are your weaknesses?
  8. How long have you been in business?
  9. Who are your key employees?
  10. Also, can you describe the experience of staff?
  11. Do I have access to the floor supervisor?
  12. Who is my main point of contact?
  13. Do I have a contact on weekends?
  14. Who do I contact for an emergency?
  15. Are you properly insured? (Check with your insurance company to confirm requirements)
  16. Can you supply 3 customer references?
  17. Are you willing to sign a non-disclosure form?
  18. What is your lead time for orders?
  19. Therefore, are you able to tackle rush orders?
  20. Should the customer supply parts or do you prefer to supply parts?
  21. Do you have aggressive discount programs with vendors?
  22. Furthermore, do you take advantage of early payment discounts with your vendors?
  23. Also, what are your payment terms?
  24. Do you accept credit card for payment?
  25. Are discounts available for early payment?
Round II:
  1. What type of equipment and tools do you use?
  2. What is your shipping policy?
  3. Could we compare discounts with UPS/FedEx to see who has the best rates?
  4. Who is responsible for damaged goods during shipping?
  5. Do you accept blanket orders?
  6. Will you inventory our raw parts or finished goods when necessary?
  7. Are you willing to purchase new tools or equipment to complete projects?
  8. Can we work with you on projections?
  9. What software do you use for inventory management and scheduling?
  10. Furthermore, is your company tech savvy?
  11. Do one or two customers represent more than 50% of your annual sales?
  12. Have you ever been sued or in a lawsuit?
  13. In addition, have you ever gone bankrupt?
  14. How do we handle damaged goods or parts not working?
  15. Can you describe your testing process and quality control?
  16. What is the company mission or vision statement?
  17. Do you have a succession plan or exit strategy in place?
  18. What makes your company stand above the competition?
  19. Also, are there facets of your business that demonstrate your commitment to your customer’s profitability?
  20. Any industry standards or certificates achieved?
  21. Do you also have a safety protocol in place?
  22. What is your capacity level?
  23. Have you experienced layoffs recently?
  24. Furthermore, are you profitable?
  25. Please explain the reason a recent customer stopped buying from you?

Asking thorough questions goes a long way with any relationship. This list is just a suggestive list of helpful questions to consider when Interviewing a Wire Harness Manufacturer.


Discreet Questions Can Save You Down the Road 

Outsourcing manufacturing operations can deliver tremendous benefits to your business. Unfortunately, there are many risks attached as well. Furthermore, let’s continue our discussion by addressing Discreet Questions to Determine Character Compatibility and Financial Viability. Asking tough questions will help narrow down your selection process.

So you have entered the interview process to select a new custom manufacturer to partner with. Therefore, now you are digging deeper into the due diligence process to see who is exactly the best fit.

Financial stability is certainly one of your absolute top concerns. If you are both small businesses, discovering actual financial figures or intimate information may be difficult to obtain. Even though this is information is critical. Especially if the project or product represents a significant portion of your sales.

So what steps or strategies can you take to discover the financial viability of this new prospect?

Important Questions to Ask Yourself 

Here are a few questions to ask yourself through this process:

  • Does the company represent itself well?
  • Do you have similar goals and a common business philosophy?
  • Also, is this a team of people with integrity that you can trust impeccably?
  • Is this a partner that is committed to your profitability and success?
  • Or are you another opportunity for the owner to support a lavish lifestyle?

Determine Character Compatibility and Financial Viability 

Here are a number of discreet questions to consider to help determine the financial viability of the company as well as the character level of ownership:

Check Spending Habits:
  1. Strike up a conversation on hobbies. Do they have expensive hobbies? Golf at Pebble Beach, mountain climbing the Himalayas, scuba diving in Thailand, flying a helicopter, bragging about their yacht… you get the point.
  2. Find out the type of car they drive. “My spouse is looking for a new car. What type of car do you drive or recommend?”
  3. If you live near the prospect, casually ask what neighborhood they live in. Sorry to get overly “stalkerish”, but finding out their neighborhood will let you know their lifestyle. Also, Google Earth may assist.
Ask for References: 
  1. Ask for bank reference
  2. ……business references
  3. ……also, character references
  4. …… as well as customer references

Do Some Research on Google and Social Media: 

  1. Google the owner to discover any past felonies, convictions or other bad news.
  2. Additionally, you may want to check their Facebook page & see what they do in their personal time.
  3. Also, check any other social media – Twitter, Snapchat, Instagram, and Pinterest.
  4. Look for Videos on YouTube.
  5. Furthermore, check mutual connections on LinkedIn.

Going the extra mile with your due diligence process will save you a tremendous amount of grief and frustration down the road.


It is Now Time to Plan a Visit and Take a Tour

So you continue plunging through the due diligence process to select a Wire Harness Manufacturer.

You have performed dozens of Google searches of “Wire Harness Manufacturer” to narrow down the field.

You have evaluated plenty of websites and social media pages until they all start to blend together.

Hopefully, several companies are standing out from the crowd.

Emails have been exchanged and phone calls have been made to break the ice.

You have also been asking plenty of tough questions and pleased with a majority of responses.

Also, there may be one or two candidates that really seem like they are head and shoulders above the rest.

You are feeling good.

Finally, it is time to plan a visit and tour each facility.

A physical visit to top candidates in person is vital to your decision. You might even want to consider a surprise visit (“Hey, I was in the neighborhood” – even if 500 miles away).

Here is an excellent article from the Harvard Business Review regarding plant tours (Even though this was written 20 years ago).

Eyes Wide Open and the Attitude of a Harsh Critic

It is extremely important to go on the tour with eyes wide open and the attitude of a harsh critic.

(Actually, this was just a great excuse to get Judge Judy into one of our blogs).

What to Look for When Touring a Wire Harness Manufacturer

Below is a list to consider when Touring a Wire Harness Manufacturer:

  1. Do you find the building and property presentable or unkempt? (Unmowed grass, disheveled parking lot, garbage, broken windows, etc…)
  2. Additionally, is the office presentable or unkempt? (Top of the line everything or dated to the 1960’s)
  3. Are you warmly greeted?
  4. Additionally, are the management, staff, and employees pleasant and welcoming?
  5. Also, do employees look happy and hustling?
  6. Are tools and equipment organized and well maintained?
  7. Furthermore, are the warehouse and inventory efficiently organized?
  8. Is the shipping dock clear of clutter?
  9. Also, are you impressed or underwhelmed with the team and operation?
  10. Are there any red flags that make you uneasy?
  11. Additionally, do employees have cell phones out?
  12. Check the kitchen area – is it clean and organized or dirty?
  13. In addition to the kitchen area, are the restrooms clean?
  14. Are there any key employees that do not come out to meet you?
  15. When evaluating the quantity and quality of staff, does the company seem to be top heavy?
  16. What are the years of service of the management team?
  17. Be prepared with tough questions regarding your product and process to determine if they are indeed experts in their field (see #6).
  18. Is the Wire Harness Manufacturer management team short and brief with you? Is this a good sign that they are focused and busy or are they rude and distracted?
  19. On the other hand, if they meet with you for a long period are they too lackadaisical or not busy?
  20. Furthermore, do they seem eager to earn your business or desperate?
Bonus Round 
  1. Look for matching or mismatched priorities: expensive office furniture, overstaffed, excessive non-business essentials (foosball table, video games, keg parties, etc).
  2. Get a gauge on morale at the company.
  3. Does the owner wear an expensive wardrobe or jewelry?
  4. Finally, ask the owner for an opportunity to have a mutual meeting with their accountant to view audited financials. In addition, if necessary, offer to have the meeting at your expense. Could offer great ROI.

Outsourcing your production to a custom manufacturer is similar to finding quality daycare for your child. Therefore, you need to find a company that you Trust, Trust, Trust!

As the saying goes, if something is not a “HELL YEAH” then it is simply a “No”.


Supply Parts or Not to Supply Parts?

That is the Question 

(OK, that was our pathetic attempt to sound like Shakespeare).

Anyway, a common question with new customers: “What if we would like to supply our own parts?” With many custom manufacturers, this is the equivalent of bringing your own food to a restaurant and asking them to prepare you a meal.

Supplying your own products to a custom manufacturer offers several positives and negatives. Consequently, it works best to communicate clearly with the manufacturer on the pros and cons of either option.

The question is do you really save money?  Also, one-size fits all does not apply here. Furthermore, there are many variables to consider which option makes the most sense (or more importantly, makes the most CENTS).

Pros and Cons 

Let’s take a look at the Pros and Cons of supplying your own parts and components: 


Several benefits fall in your favor by taking the initiative to order and supply your own parts when outsourcing:

  1. You control the ordering process and supply chain. 
  2. Ordering your own parts allows you to also have full disclosure of pricing on the cost of goods.
  3. First-hand knowledge of availability or stock-outs of your product.
  4. Furthermore, you have better control over delivery times. 
  5. Negotiating your own discounts with the vendor. 

However, ordering or supplying your own parts may be welcomed by the Wire Harness Manufacturer. On the other hand, this approach could be disruptive to the manufacturer. Furthermore, there are a few negatives to consider:

  1. The time you spend ordering parts.
  2. As well as the time you spend coordinating deliveries.
  3. Lost opportunity of volume discounts available to the manufacturer due to their purchasing power.
  4. Product knowledge and expertise that the manufacturer possesses.
  5. Also, the variety of shipments arriving at the manufacturer on different days throws off their production schedule for your product.
  6. The receiving department at the manufacturer must be informed of delivery. This communication is crucial for the manufacturer in order to properly schedule the production of your products.
  7. The manufacturer must implement a means to monetize the receipt of your goods that you have delivered. It is in neither parties interest to not account for labor, handling, and the overhead expense of receiving and storing goods. So, are you really saving money?
Where is Your Time Best Spent? 

Wire Harness Manufacturer

An important question to ask yourself: Is your time better spent focusing on other areas of the business? Furthermore, did you partner with a company that you trust enough to delegate the purchases?

In addition, you partnered or hired the custom manufacturer due to their proficiency, expertise, and ability to deliver a quality product on time. Is it worth your time, hassle and energy to locate new vendors and product? Especially in areas that are either new to you or where you are lacking purchasing power and strong vendor relationships.



 New Wire Harness Manufacturer  

Finally, selecting a Wire Harness Manufacturer does not need to be a stressful process. Outsourcing Your Wire Harness Assembly can generate significant profits for your business.

Especially partnering with an experienced company with a seasoned staff. This decision lends a tremendous competitive advantage for your company. Also, selecting a Wire Harness Manufacturer that completes projects with the highest quality, effective pricing, and on-time delivery dramatically boosts to your bottom line. Therefore, teaming up with a company dedicated to your success is critical.

Wire Harness Manufacturer Checklist 

To recap, here is a checklist of company traits to pursue when finalizing your search for a new Wire Harness Manufacturer:

  1. Superior Quality
  2. Maintaining an Impeccable Customer Scorecard
  3. Also, fast Turnaround Times
  4. Competitive Prices
  5. Seasoned Staff
  6. Company Experience
  7. Short Lead Times
  8. Agile and Flexible
  9. Company Culture Dedicated to Customer Satisfaction
  10. Lastly, a Deep Commitment to Safety

Wrapping It Up 

Wire Harness Manufacturer

Ok. Hopefully, you are now happy as can be with your new Wire Harness Manufacturer.

Furthermore, as with any outsourcing partner, work diligently to maintain healthy and constant communication. Also, be clear about goals and expectations. This will also help guarantee a long, happy and prosperous marriage.

Thank you for taking the time to read our Tips for Selecting a Wire Harness Manufacturer.

Additionally, click on these links for more info on electronics manufacturing and ground straps.




Also, check out these helpful links:

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Made to order ground straps

Bonding and ground straps are terms that people often make the mistake of using interchangeably. However, they are not the same thing. While their jobs are similar in nature there are very important differences. Also, their functionality is almost opposite to each other.


In this particular example, bonding means attaching two pieces of metal from a machine to connect them permanently. Joining these pieces creates an electrical path between the two pieces. Therefore, the two metal pieces (and in turn their machinery) will have the same electrical potential. Another example of bonding would also eliminate electrical buildup between two machines.

The main reason for bonding within electrical equipment is to ensure the safety of workers. If a person connects two pieces of machinery there is a potential for electrical shock. However, if there is bonding between the two pieces there should be a protection to anyone interacting with the machines.  The bonding of electronics also works with the grounding of those electronics.

Ground Straps

To continue on with the above example, you will have to ground the metal components or equipment after bonding. You accomplish this by attaching a ground strap to components while also attaching the ground strap after the bonding process. With this method, once the ground strap is attached to ground and all the other metal components are bonded together they would all be at the same ground potential.

Even when there is bonding between two machines there should also be a ground to a neutral point like the earth or another piece of material that has already been through the grounding process. Ground straps are a tool used for this. As stated in our blog on the uses of ground straps, ground straps are important because they protect people and electrical devices from electrostatic discharge (ESD).

If a short circuit occurs a ground strap will redirect the electrical charge to a ground as opposed to allowing it to travel through a person who is interacting with the machine. As well as protecting people, a ground strap can also protect any other machine from the shorted-out circuit. A ground strap will provide a safe route for the electricity to travel rather than going into another machine and causing a chain reaction of shortages.

Connect with us

To order any of our Ground Straps you can go to our ground strap page

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Let’s talk Heavy Duty Ground Straps! Not just any type of Ground Straps.

We mean HEAVY DUTY Ground Straps. Hard Core. Fierce. Down and Dirty. Rugged. Tough as Nails. Relentless. Tenacious.

Climbing Mount Everest…..without any oxygen….type of Heavy Duty Ground Straps.

Hall of Fame Linebacker Heavy Duty Ground Straps: Think Dick Butkus, Mike Singletary, and Brian Urlacher (for all of the Bears fans out there). Jack Lambert and Lawrence Taylor type of tough (for the non-Bears fans).

Running A Tough Mudder……backward……in ski boots……on a 100-degree day………without water………….being tasered the entire course….while also being chased by pit bulls…….. type of tough.

We are talking, “Grandma Would Be Proud of You” Type of Heavy Duty Ground Straps.

Buy Heavy Duty Ground Straps Direct & Save!

No Middle Man! Definitely No Additional Markups! Therefore, why buy retail when you can purchase directly from the manufacturer?

We make’em & ship’em. Quick!

With 33 years experience serving Fortune 500 Companies. Mid-size manufacturers. Small business owners.  As well as everyone in between, our team tackles any project.

Need 1 or 500,000? No problem.

Custom Orders? Absolutely.

Blanket Orders? We would be happy to.

Wide Selection of Heavy Duty Ground Straps

Heavy Duty Ground Straps

These Heavy Duty Ground Straps are corrosion resistant. Furthermore, the tinned copper braided wire offers durability, flexibility and maximum conductivity.

For your convenience and fast service, we offer a line of in-stock Heavy Duty Ground Straps. Currently, our stock lengths include 4, 8, 12, 16 and 20 inches.

Also, custom sizes and terminals available as well. We like to tell our customers, “Any Size for Any Job!” Therefore, we would love to discuss your project. Especially challenging jobs. 

In addition, you are always welcome to utilize our FREE WIRE HARNESS ESTIMATOR.

Made in the USA 

Take advantage of the tremendous benefits when purchasing Heavy Duty Ground Straps Made in the USA:

  • Low Minimums: Avoid the huge financial risks that go along with purchasing large quantities with importing
  • Short Lead Times and Quick Turnaround (No ocean to cross when you buy domestic)
  • Avoid the Hassle of Clearing Customs
  • Eliminate Unnecessary Duties and Import Fees
  • Also, Improve Inventory Turnover
  • In Addition: No Letter of Credit Needed
Agile and Flexible 

Furthermore, our customers value and appreciate the agility and flexibility offered when buying directly from the manufacturer. We consider ourselves an extension and partner of your business.

  • Free samples available upon request
  • Fast Turnaround
  • Highly Skilled and Experienced Team
  • Buying power that lowers your costs
  • Multiple shipping options also reduces your costs
  • In addition to our near perfect customer satisfaction levels
  • All Due to our 33 years of experience

Finally for more info on electronics manufacturing as well as all of the other fun things happening at Falconer Electronics, please check out our blog here.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!






Grounding? You mean I’m grounded?! The word “grounding” is certainly never one you want to hear as a teenager. Especially from your parents. Grounding means no car. No smartphones, tablets or other devices. No sleepovers. You are basically under house arrest. Oh, the humanity! It certainly pays to mind your manners. In other words, try to stay out of trouble.

Anyway, the term “Grounding” for this discussion refers to safety. Phew! Great stuff to discuss when it comes to electrical products. Grounding returns live electrical circuits to the earth or ground. This keeps individuals safe from live wires or currents.

Grounding = Electrical Safety

Grounding wires prevent electric shocks, fires and even fatalities. It sends the current back to the ground making it harmless. Ever blow a fuse or trip a circuit? That “inconvenience” just saved you from a potential disaster.

So next time a circuit breaker pops, be grateful. Sure it stinks to stop what you are doing. Especially in the middle of making dinner or some other important project. As you go searching for which circuit to flip, take a moment to appreciate that the safety feature worked causing no harm to your household.

When you look at any outlet at your home or office, notice that there are three openings? Ever wonder why? Well, the left slot serves as neutral. The right slot means HOT. The third hole is for the ground plug. Any electrical device with three prongs means that product includes a ground cord.

Safety Tip: NEVER cut off the ground plug to fit an outlet. Not a good idea under any circumstance.

Without the ground cord, the electric current could flow through your body to find gound. Certainly, not a welcomed experience.


You can always visit our blog for more information on electrical products and safety. Also, you can check out product information on grounds straps here.

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What is a Surge?

A surge is an increase in voltage significantly above the design level in a flow of electricity. Any household product can also cause a power surge in homes. The main causes can be from a storm or single lightning strike near your home.  Also, power lines and utility poles that are not working properly due to damage by animals, tree limbs, and car accidents. The burst of electricity can enter your home by telephone or power lines. This can cause an overload of power that needs to escape somehow.

Why Use a Protector?

Surge Protectors are extremely important in the home. They can be found almost everywhere, especially in outlet strips. Outlet strips can be for anything you can imagine in the home. Without proper protection, they can also harm your electronics if an electrical storm were to come about. Current electronics are much smaller and more delicate than older machines and are therefore more sensitive to current increases. It’s a good idea to use surge protectors for high-end electronic equipment, such as entertainment center components. By using this protection, generally, you can extend the life of a device.

Key Tips and Tricks!

Here are some tips and tricks to keep in mind when choosing your protection!

  1. Always look for outlet strips that are properly tested to the standards of a UL certification.
  2. Don’t overload your outlet strip, this can cause too much electricity to run through the outlet strip at one time. This can cause fires, electric shock, and many more dangerous situations.
  3. Make sure to check your outlet strips on a regular basis. A strong enough electrical current could have broken the protection without your knowledge.
  4.  Pay attention to how many joule ratings your outlet strip has. The higher the rating the better!
  5. Make sure you have an indicator light. This is for proper grounding in your strip.


Stay Connected with us!

You can click here for more information on our Commercial Power Strips.

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Groundhog Day! A wonderful time of year. Ski and snowboarding season is still at full throttle. Yet, the whispers of spring are just around the corner.

Not to mention, a reminder of one of our favorite movies of all time, Groundhog Day. A classic film with Bill Murray that came out 25 years ago in 1993. Where did that time go? If you are not familiar with this timeless treasure, do yourself a favor and watch it soon. Being Groundhog Day, no time better than the present.

Groundhog Day: A Shocking Experience 

Well, Groundhog Day is also a perfect time to kick off our series on staying grounded with ground cords and ground straps. In other words, keeping safe. Always remember safety first.Groundhog

A toaster in the tub? Of course, not a good idea. Water and electricity are typically not friendly to each other (understatement of the day). As a matter of fact, any electrical device in the tub will be a shocking experience. Not in a pleasant way though.

Electrical currents love to travel, fast. The human body does not serve well as a carrier of electric currents. Wires, on the other hand, they LOVE electrical currents flowing through them. Think of all of the many benefits that electrical currents offer.

Electrical currents keep our homes warm, rooms lit with proper lighting, refrigerators running, microwaves heating and…well….you get the idea. The device that you are reading this with has wires inside that are tidily tucked away out of harm’s way.

No plans for the weekend? No problem. Make a nice cup of hot chocolate. Grab milk out of the fridge, mix with cocoa and heat up on the stove. Throw a bag of popcorn in the microwave. Settle in for a Winter night with Bill Murray and Groundhog Day on your TV or tablet. It is a great day to appreciate ALL of the electricity flowing safely through your home keeping you warm, nourished and entertained.

Lastly, just remember, spring is just around the corner. The Groundhog says so.

For more info on electronics manufacturing, please connect with us on FacebookTwitterGoogle+, and LinkedIn.


There are multiple reasons to need commercial power strips. The most important of these have to do with their uses and their reliability.

Power Strips are Rigorously Tested to UL Standards

 UL Power Strips CSA ETL

Safety is the number one concern, especially when interacting with electricity. Therefore, when using a power strip, it is important to know that it can perform its intended duties safely. The testing laboratories conduct on products are rigorous to guarantee that there are no safety concerns. Each of the tests that these labs perform on a commercial power strip ensures its reliability.

Our Power Strips are Durable and Reliable

Our Commercial Power Strips power product displays in some major brick and mortar retailers. These retailers include businesses such as Walmart and Lowe’s. These retailers have worked with us for years because our products are reliable. Every time that you enter one of these retailers you see electronic displays showing working products. Many displays need to have power running to them. Without reliable power strips, those displays would still hold these products. But really, who wants to see a display sitting there doing nothing?

We Offer a Lifetime Warranty

Today there are a lot of disposable items. Customers expect to have to replace their home electronics within a range of five to ten years.  Therefore, seeing warranties on products have become a rare and surprising thing.  A lifetime warranty has especially become the unicorn of the electronic industry. That’s what sets our products apart from others. Not only have our products been through safety testing as previously stated but they also have a lifetime warranty.

There are Many Versatile Uses

Many times, when we see power strips in retail stores there is one standard option for how many outlets are available. This limits how many electronics you can safely plug into them. As an alternative, we offer four different options for power outlets. A small four outlet line can be used for living room gadgets like a television, disc player, computer, and lamp. Alternatively, a larger power line of twenty outlets can be useful in a workshop or craft room where you need multiple tools, lighting, and fans plugged in at the same time safely. Also, we give the customer the option of custom designing their own power strip.

Keep In Touch

To learn more about UL, ETL, and CSA you can read our blogs on the testing labs.

You can click here for more information on our Commercial Power Strips 

You can also get great DIY ideas on our Facebook page!

For more info on electronics manufacturing, please connect with us on TwitterGoogle+, and LinkedIn.



Magnetic Based Work Lights

Are you cold today? Freezing? January is certainly living up to chilly expectations. In most parts of the country anyway. Well at Falconer Electronics, we like to Think Warm. Even though thermostats in our neck of the woods are flirting with single digits, things are heating up here. We like to think we have an extremely Magnetic Team here at Falconer Electronics. We also like to light things up! Of course, the pun is intended in this case. Especially since Falconer Electronics expanded into Magnetic Based Work Lights last year.

Magnetic Based Work Lights Allow You to Work Hands-Free

Magnetic Based Work Lights

Magnetic Based Work Lights offer you tremendous value. Working hands-free allows you to tackle any job. With both hands available to conquer your project and plenty of additional light, you are now unstoppable! Look out, Tim Allen (Wow, that was SO 1990’s). How about “Flip or Flop” on HGTV?

Anyway, we work extremely hard to help BRIGHTEN your day. Oops! Another pun. Sorry, we just can’t help ourselves. These Magnetic Based Work Lights are created and assembled right here in the USA. Rugged. Durable. Long lasting.

These heavy-duty work lights deliver the necessary lighting to tackle challenging projects. Perfect for industrial and warehouse settings. Lights also work great for the office and home use. Especially for those of you weekend warriors who love to tinker in the garage.

Looking for Trouble? We have Trouble Lights hoping to keep you out of trouble. In addition, check out these Magnetic Spotlights that offer a wide range of solutions.

LED Flashing Lights that work perfectly as a safe alternative to dangerous roadside flares. We also manufacture MSHA-approved LED Mine Lights and much more.

For more info on electronics manufacturing as well as all of the other fun things happening at Falconer Electronics, please check out our blog here.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

An interesting and unexpected phone call arrived. The caller asked, “Can I purchase one of your Metal Power Strips?” Hmmm, that was odd. This was a consumer who inspected one of our power strips powering a display at a major retailer.

We have been producing killer Metal Power Strips for over 30 years. Strictly as product display units. Not for resale or consumer sales.

Then another call came in. Then another.

Shoppers began taking notice of our Metal Power Strips powering retail product displays. Primarily in use at major retailers. Consumers were contacting our office to purchase these high-quality Metal Power Strips direct.

4 Outlet Commercial Power Strip 8 Outlet Commercial Power Strip

Heavy Duty Metal Power Strips for Consumers

Major retailers trust the Falconer Electronics brand for the ruggedness, durability, and reliability. Since 1985, our customers have included Walmart, Lowe’s and many more. These Metal Power Strips work relentlessly powering product displays all throughout the U.S. and Canada.

Due to high demand, these Heavy Duty Metal Power Strips are now available for sale at

As an American Manufacturer, we take tremendous pride in delivering a quality product. On time. Every time.

All metal power strips are produced and assembled in the USA at our facility in Falconer New York. Available in a line of four sizes.

In addition, we keep our costs as competitive as possible. This is done by sourcing products domestically and globally. We start with local vendors first. For example, each Power Strip is manufactured with U.S. fabricated steel from a local steel fabricator. This relationship offers incredible flexibility and speed to tackle any project.

Also, all power strips are tested to rigorous UL standards.

Need a Custom Size? 

Do you have a unique project that requires a custom made heavy duty power strip?

If so, let’s chat! We pride ourselves on offering product solutions. Customers face tough challenges. We strive to work closely with you to solve those problems.

As a custom manufacturer, our team, infrastructure, and experience offer the flexibility to conquer nearly any project to fit your needs.

No job is too big. No job is too small.

Call us today to discuss your project requiring a Metal Power Strip. Since our humble beginnings in 1985, we always consider it a sincere privilege to serve our customers.

For more info on electronics manufacturing, please connect with us on FacebookTwitterGoogle+, and LinkedIn.


SHARP renewal

From left, Tim Songin, Safety Compliance account manager; Gary Baumann, Falconer Electronics; Cheryl Stanford, Falconer Electronics; Jan Jackson, Falconer Electronics; and Roger Hall, Falconer Electronics founder and president; outside of Falconer Electronics, located at 421 W. Everett St., Falconer, to recognize the business’ recertification into the Safety and Health Achievement Recognition Program. Submitted photo

Falconer Electronics Maintains SHARP Certification

FALCONER NY — Falconer Electronics was recently recertified into the Safety and Health Achievement Recognition Program, also known as SHARP, for maintaining a safety and health program among the most-effective in the nation.

The recertification involved a three-way effort between the state Department of Labor, Falconer Electronics and Safety Compliance Inc.

Joe Budzich, state Department of Labor health auditor, and Brad Hahn, state Department of Labor safety auditor, completed the recertification. Falconer Electronics achieved its initial certification into the program in 2002 and has maintained the certification since. In addition to recognizing the company for having a highly effective safety and health program, acceptance into the SHARP also grants the company an exemption from routine OSHA inspection that can be renewed annually.

The company was founded in 1984 and incorporated in 1989, at which time it employed 10 people. Falconer Electronics manufactures circuit boards and electro-mechanical assemblies at a 30,000-square-foot facility at 421 W. Everett St. in Falconer. The company’s first assembly project was with AT&T and involved the development and production of security and temperature control for telecommunications cabinets. Falconer Electronics works for a number of well-known manufacturers and customers, often as a private label source for various components and complete assemblies. Additionally, the company serves the automotive industry, having worked in partnership with a customer prototyping and then producing the first LED lighting assemblies for heavy-duty automotive applications.

The company has completed more than 12 years without a day away from work accident.

“We are very happy and proud of our personnel. Since 2005, we have had zero days away from work injury cases. We would like to thank Brad Hahn and Joe Budzich from the state Department of Labor and Rick Shields and Tim Songin from Safety Compliance for their efforts and support maintaining our certification,” said Roger E. Hall, Falconer Electronics founder and president.

Tim Songin, Safety Compliance account manager, credited continual rotation on the safety committee as an important part of the company’s success.

” Consistency throughout the company’s safety program is at the forefront every day. Gary Baumann, Jan Jackson and Cheryl Stanford played an intricate part in this renewal,” said Songin, who co-chairs the committee.

The Falconer Electronics safety committee, composed of both line and management personnel, meets on a monthly basis and oversees the company’s written safety policies, annual employee training sessions and facility safety inspections. An action plan is drafted at the end of each year outlining the company’s monthly goals for the upcoming year.

“I am very proud that Falconer Electronics has once again been recertified into the SHARP. This is the result of all parties involved maintaining a high standard of safety in our work environment and a true team effort,” said Baumann, Falconer Electronics safety manager.

The company’s certification runs through 2019 at which time it will be up for renewal.


American Wire Gauge or AWG is the standard way of measuring wire gauges in the United States. However, in other countries, they use a different standard of measuring, SWG or British Imperial Standard Wire Gauge, for example. The availability of two different standards has led to a difference in how wire gauges are measured and what standard sizes of wire are used.


AWG is the standard for measuring wire in the United States. This standard is defined by the diameter of the electrical wire that is being measured. Therefore, it is the physical size is what matters most. Also, the larger the physical size of the wire the smaller the wire gauge according to the AWG measurements.


SWG was the legal standard for measuring wire in the United Kingdom as of 1884. All of the SWG measurements are in metric sizes. In most cases of use of the SWG measuring standard the sizes will be rounded up which does affect the accuracy.


In a lot of ways, AWG and SWG standards are similar. Most noteworthy, both standards are based on the physical size of the wire being measured. Also, both share common wire numbers that express those physical sizes. Finally, metal measuring plates are used to determine the size of the wire.


The most obvious difference is the standard of measurements. AWG is recorded in what is referred to as the imperial system of measurement. This system of measurements is in inches. Therefore, the American standard is different from the SWG system which uses the metric system of measuring. When looking at the charts below there are slight differences in the calculations between the two systems. Especially relevant is the difference that can be seen between the 12 and 24 gauges. These are very common sizes of wire and the chart shows a very drastic difference amongst the size measurements.


Reference charts:




Wire Number
Imperial Standard
Wire Gauge
Wire Gauge
gauge ins. dia. ins. dia.
0000000 (7/0) 0.5000
000000 (6/0) 0.4640 0.580000
00000 (5/0) 0.4320 0.516500
0000 (4/0) 0.4000 0.460000
000 (3/0) 0.3720 0.409642
00 (2/0) 0.3480 0.364796
0 (1/0) 0.3240 0.324861
1 0.3000 0.289297
2 0.2760 0.257627
3 0.2520 0.229423
4 0.2320 0.2043
5 0.2120 0.1819
6 0.1920 0.1620
7 0.1760 0.1443
8 0.1600 0.1285
9 0.1440 0.1144
10 0.1280 0.1019
11 0.1160 0.0907
12 0.1040 0.0808
13 0.0920 0.0720
14 0.0800 0.0641
15 0.0720 0.0571
16 0.0640 0.0508
17 0.0560 0.0453
18 0.0480 0.0403
19 0.0400 0.0359
20 0.0360 0.0320
21 0.0320 0.0285
22 0.0280 0.0253
23 0.0240 0.0226
24 0.0220 0.0201
25 0.0200 0.0179
26 0.0180 0.0159
27 0.0164 0.0142
28 0.0148 0.0126
29 0.0136 0.0113
30 0.0124 0.0100
31 0.0116 0.0089
32 0.0108 0.0080
33 0.0100 0.0071
34 0.0092 0.0063
35 0.0084 0.0056
36 0.0076 0.0050
37 0.0068 0.0045
38 0.0060 0.0040
39 0.0052 0.0035
40 0.0048 0.0031
41 0.0044 0.0028
42 0.0040 0.0025
43 0.0036 0.0022
44 0.0032 0.0020
45 0.0028 0.0018
46 0.0024 0.0016
47 0.0020 0.0014
48 0.0016 0.0012
49 0.0012 0.0011
50 0.0010 0.0010
51 0.00088
52 0.00078
53 0.00070
54 0.00062
55 0.00055
56 0.00049


To learn more about American Wire Gauge measurements check out our blog WHY DO WIRE GAUGE SIZES SEEM TO WORK BACKWARDS?

For additional information on the Wire Harness Assembly Process, please click the links below:

You can also get your own custom wire harness estimate with our Wire Harness Estimator

In addition, click here for an Instant Quote on Braided Ground Straps.

Finally, let’s get social. Please connect with us on FacebookTwitter, and LinkedIn.

Heavy Duty Outlet Strips

Falconer Electronics has been producing high-quality Heavy Duty Outlet Strips since 1985. Rugged, tough and tested by rigorous UL standards. In particular, you can find our outlets powering product displays at major brick and mortar retailers. From popular demand, our team created a new line of outlet strips to sell to the public. These reliable power strips can be purchased directly from our new e-commerce store (click here).


When you purchase a Commercial Power Strip from Falconer Electronics, you have the confidence that your project is powered by a durable and reliable product. All Heavy Duty Outlet Strips are manufactured with U.S. Fabricated Steel and assembled in the USA. Power Strips at Falconer Electronics come with a Lifetime Manufacturer Product Warranty.

Buy Direct and Save! 

Buy Direct! No Middleman! No Additional Markups! These dependable and long-lasting commercial outlet strips are only available on Take advantage of the tremendous savings when you buy directly from the manufacturer at Falconer Electronics.

Major Retailers Trust Falconer Electronics 

Since 1985, many of the biggest names in retail have put their trust in Falconer Electronics for Commercial Power Strips. Our Heavy Duty Outlet Strips power literally thousands of product displays in major brick and mortar retailers across the U.S. at Walmart and Lowe’s. You can now purchase the same high-quality Commercial Power Strips that major retailers have relied on for over 30 years.

High Quality and Efficient 

The F0216 Series Power Strip offers an efficient method of power distribution for workbenches, wall mount or other applications. Includes 5-15R output receptacles arranged to accept equipment plugs with minimal outlet blockage. Power strips include a 6 foot AC line cord with adjustable mounting brackets for a variety of temporary mounting applications. Corded, multi-outlet strip reduces cabling chaos and enables the connection of multiple electrical devices to a single AC wall outlet. Features rugged USA fabricated steel housing, 15 amp resettable circuit breaker/switch and industrial gray powder coat.


cETLusUL1363 Relocatable Power Tap

Thank you for reading our announcement on our new line of Heavy Duty Outlet Strips. Also, for more info on electronics manufacturing, please connect with us on FacebookTwitterGoogle+, and LinkedIn.