The automotive industry is turning to artificial intelligence to replace slow manufacturing methods. Car cable supplier COFICAB has partnered with data science firm DareData Engineering to change how electrical wires are made. The teams want to transform traditional manufacturing into a modern process driven by live data and digital simulation. As factories across Europe embrace these automated workflows, sector analysts at devs.com.pt recently reported that smart industrial automation is quickly becoming a need to stay competitive.
This collaboration directly addresses the slow pace of product development through the COFICAB DareData automotive cable testing project. Right now, designing a new automotive cable can take up to 16 weeks because technicians must run many rounds of physical laboratory tests. If a sample fails, engineers have to repeat the whole process. This cycle wastes time and expensive materials. COFICAB is solving this problem by using advanced machine learning models to test thousands of design scenarios virtually.
MeltAI and CableAI Take Over the Factory Floor
The new technology setup relies on two main software systems called MeltAI and CableAI. In the production area, MeltAI automates the extrusion process, which is how insulating plastic is applied to wires. The system uses an AI accelerated cable insulation simulation loop to optimize material thickness in real time. This automated quality check reduces scrap waste and saves hundreds of euros per machine every day.
In the research and development departments, CableAI replaces physical prototyping with digital twins. This automotive wiring harness machine learning platform replicates how complex physical materials behave under different conditions. The software allows engineering teams to analyze up to 50,000 combinations of wire shapes and chemical formulas in a few seconds.
Massive Speed Up for Industrial Engineering
According to project data, this predictive modeling for electrical cables runs up to 10,000 times faster than traditional lab methods. The platform also includes a natural language AI assistant. This helper lets technicians talk directly to the simulation software to ask for quick optimizations.
The project started at COFICAB's facilities in Portugal, but the company plans to roll out the software globally. Because this technology solves general design and simulation problems, it could soon expand beyond automotive parts into aerospace and pharmaceutical manufacturing. To track how these automated design tools are changing European supply chains, engineering teams can check the latest global tech news for updates on industrial tech deployments.
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