Caton is a custom high-voltage cable assembly manufacturer supporting design engineers responsible for electrical integrity, voltage performance, and long-term system reliability. We design and manufacture high-voltage connectors and cable assemblies from 1 kV to 250 kV under AS9100-certified processes, with validation through partial discharge testing and environmental stress testing to ensure your system performs in the real world, not just in simulation.
You own performance.
Our role is to remove uncertainty from the high-voltage interface, so your system behaves as designed, not just as modeled.
We do not wait for drawings to be finalized before engaging. The highest value we provide happens early, when geometry, insulation systems, termination methods, and voltage margins are still flexible.
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What We Solve for Design Engineers
High-voltage systems fail for predictable reasons:
- Inadequate insulation design
- Poor termination geometry
- Uncontrolled corona and partial discharge
- Manufacturing variation that alters electrical geometry and field stress
- Assumptions that only work in theory
We exist to prevent those failures from becoming program risks.
You get engineering support that understands:
- Electric field stress
- Corona inception and suppression
- Insulation system design
- Mechanical stability under voltage
- Long-term degradation mechanisms
Where We Add the Most Value
We are most valuable when you involve us:
- During early design reviews
- When selecting insulation systems and materials
- When defining voltage margins
- When packaging high-voltage into constrained mechanical spaces
- When transitioning from prototype to controlled production
This is where design stability is created.
How We Work With You
You work directly with Caton engineers.
No filters. No sales translation.
We support:
- Design-for-manufacturability input
- Corona mitigation strategies
- Termination and interface design
- Failure analysis and corrective design changes
- Transition from development builds to AS9100 production
When your design is released, it stays stable.
What You Can Expect
From a design standpoint, you get:
- Technical collaboration, not just quote support
- Real-world manufacturing constraints incorporated into design
- Stable electrical performance from 1 kV to 250 kV
- Consistent geometry and insulation control
- Documentation that supports qualification and validation
You get fewer surprises during test and qualification.
Why Engineers Choose Caton
Engineers stay with Caton because:
- We understand high-voltage behavior, not just assembly
- We protect their designs from manufacturing-driven failure modes
- We support sole-source programs responsibly
- We keep electrical performance consistent across years of production
Our job is to make your design boring in operation.
Stable. Predictable. Repeatable.
Typical Engineer Engagements
Design engineers involve us when:
- Developing new high-voltage systems
- Pushing voltage or packaging limits
- Solving corona or insulation breakdown issues
- Qualifying a new platform
- Stabilizing a design for long-term production
