Engineering & Manufacturing
Engineered with purpose. Built with precision.
We design and manufacture professional power distribution units, cable assemblies and custom power solutions around the requirements of their application. Our engineers translate customer needs into practical designs, supported by controlled assembly, measurement and testing throughout production.
Made in EU.
Inside Tesla Tech
See how we build.
See the people, machinery and assembly processes behind Tesla Tech PDUs and cable assemblies.
Application engineering
The right solution starts with the right questions.
Every project starts with understanding what the equipment needs to do, where it will operate and how it will be used.
Electrical loads, connections, protection, monitoring and available space define the technical requirements. Transport, installation, control visibility and access for servicing shape the practical details.
This approach guides both our standard products and customer-specific solutions.
Use the right tool for the job.
We select the enclosure, connections, protection and functionality to suit the operating environment, from permanent installations to touring systems and repeated outdoor deployment.
Product development & integration
More capability. Purposeful design.
We continuously develop our products to bring useful functionality into compact, practical formats. Electrical architecture, connection layouts, protection, monitoring and mechanical construction are developed together around the requirements of the application.
Compact integration
We combine distribution, protection and monitoring in compact formats, with clear layouts and straightforward operation.
Modular thinking
We develop modular configurations around the required connections, outputs and deployment needs, so each product provides the functions its application requires.
Practical access
We position connections, controls and internal components for installation, inspection and servicing, considering access alongside space efficiency.
Manufacturing & assembly
From components to complete products.
Our manufacturing work brings together component preparation, assembly and checks across power distribution units and cable assemblies. Dedicated machinery, controlled working methods and purpose-built tools support consistent execution.
Power distribution units
From precision-machined enclosures to fully wired distribution units, we bring mechanical manufacturing and electrical assembly together in-house. Dedicated machinery, controlled processes and practical design details support consistent quality, durable construction and straightforward servicing.
- Enclosure & flightcase manufacturing: aluminium laser cutting, HDPE CNC machining, forming, welding and flightcase construction.
- Finishing & identification: edge finishing, engraving and UV printing for clear markings and a refined finish.
- Electrical assembly & sealing: protection devices, connectors and wiring harnesses installed with controlled tightening torque and product-specific sealing processes.
- Comprehensive final testing: every completed PDU undergoes full testing before release.
Cable assemblies
We manufacture professional power and multipin cable assemblies using automated preparation equipment, precise termination methods and dedicated assembly tools. From accurate cable lengths to secure connections and clear identification, each step supports reliable operation and efficient handling on site.
- Cable preparation: controlled drum feeding, precision cutting, stripping and coiling.
- Contact termination: contact and ferrule crimping matched to the cable and connector system.
- Assembly & identification: connector assembly, tightening to specification, length labelling and custom heat-shrink sleeves.
- Comprehensive final testing: every completed cable assembly undergoes full testing before release.
Consistency is built into the process.
Purpose-built machinery
We use automated and semi-automated machines for dedicated production tasks. These support repeatable operations, consistent quality and efficient throughput across our manufacturing work.
Controlled assembly
Specified tightening torque matters. We tighten screw connections and screw-type electrical terminals to the relevant manufacturer’s requirements, bringing a controlled approach to mechanical and electrical assembly.
Tools developed for the task
We develop dedicated tools and assembly aids around the requirements of our products and processes. These help make production tasks more precise, repeatable and efficient.
Lean production
We continuously refine our workflows to reduce unnecessary handling, movement and process steps. This helps work move efficiently through production while maintaining attention to quality at each stage.
Quality checks & documentation
Quality throughout the process.
Quality starts with the manufacturing method and carries through to final verification. Documented procedures, checks during assembly and comprehensive final testing help ensure that every product is built correctly and performs its intended functions.
Production checks
We develop, test and implement our manufacturing procedures before introducing them into production. These procedures define the assembly sequence, working methods and inspection points needed for consistent results. Checks during assembly verify workmanship and conformity with the product specification, with any issues corrected before the product moves forward.
Product testing
Every completed product follows a test checklist tailored to its design and configuration. Visual and mechanical inspections are combined with electrical safety and functional testing to verify assembly quality, connections and intended operation.
Our test programme includes Portable Appliance Testing (PAT) where applicable and routine verification of completed power distribution units. Comprehensive final testing is the last stage of production, with results documented and acceptance criteria met before release.
Identification & documentation
Clear product identification and connection markings support correct installation, operation and servicing. Products are supplied with user instructions and the applicable conformity documentation.
For power distribution units, this includes a routine verification report and the EU Declaration of Conformity covering the product. The report records the completed verification, while the user manual provides the information needed for safe installation, use and maintenance.
PROCESS
FROM REQUIREMENTS TO A FINISHED SOLUTION.
- 01
UNDERSTAND THE APPLICATION
We begin with what the equipment needs to do, where it will be used and how the production team will operate it.
- 02
MAP THE COMPLETE POWER GRID
We review the power source, loads, connection points, cable distances, indoor or outdoor conditions and operational workflow.
- 03
DEFINE THE DISTRIBUTION ARCHITECTURE
We recommend the required main, intermediate and final distribution units, together with the cable infrastructure connecting them.
- 04
COORDINATE THE PROTECTION LEVELS
We define the protection concept, fault isolation, monitoring and selectivity requirements across the distribution structure.
- 05
DEVELOP AND ITERATE THE SOLUTION
We refine the technical configuration, connections, internal layout and external design with you through several review rounds.
- 06
MANUFACTURE, TEST AND DOCUMENT
Following final approval, the equipment is manufactured, assembled and tested in the European Union. The required technical documentation is prepared for the completed solution.
Work with our engineers
Tell us what your equipment needs to do.
Share your application, operating environment and technical requirements. Our team can help identify a suitable standard product, define a configuration or develop a custom solution.