Barcar Manufacturing, Inc.

Barcar Manufacturing, Inc., a for-profit small business electrical components manufacturer based in Elburn, Illinois, supplies cable assemblies, wiring harnesses, electrical connectors, and related electromechanical parts to the Defense Logistics Agency as a prime contractor, competing predominantly in full-and-open procurements without set-aside designations on individual task orders, though several of its underlying indefinite delivery contracts carry Total Small Business set-aside vehicles.

Barcar Manufacturing has built a sustained federal footprint centered on DLA Aviation and DLA Land and Maritime. The top five customer agencies account for 89% of recent awards by count and 93% by combined potential value, led heavily by DLA Aviation (585 awards, $22 million combined potential value) and DLA Land and Maritime (250 awards, $1.5 million). The company also serves the Department of the Army, Department of Defense's Materiel Command, and DLA Troop Support. Award volume has remained relatively steady over the past five years — 28 awards in 2022, declining to 22–23 in 2023–2024, then recovering to 27 in 2025 — with only two awards recorded in 2026 to date. Total historical awards across all federal sources number 1,294 primes (100% of the footprint), reflecting decades of consistent engagement since first federal award in 1980.

Barcar's concrete capability portfolio centers on electrical component and electromechanical assembly manufacturing for defense logistics applications. Representative recent work includes a $689,255 firm fixed-price purchase order from DLA Aviation (December 2022) for specialized cable assemblies; a $459,030 purchase order (July 2023) for wiring harnesses; a $479,852.95 delivery order (October 2024) for special purpose cable assemblies under IDC SPE4A621D0284; a $464,294.30 delivery order (September 2025) for cable assemblies; and a $185,076.72 delivery order (October 2025) for wiring harness production. Smaller routine orders range from under $200 to tens of thousands of dollars for connectors, plugs, receptacles, cable assemblies power, terminal lugs, bushings, springs, and headlights. The company supplies parts critical to military aircraft, combat vehicles, and maritime vessels within DLA's $18 billion annual aviation supply chain.

Barcar holds multiple active Indefinite Delivery Contracts with DLA Aviation spanning ceiling values from $250,000 to $2.6 million and performance periods extending through 2030. The largest vehicle, IDC 4610079935 ($2.6 million ceiling awarded August 2021, extended through August 2026), focuses on cable assemblies, power cables, and wiring harnesses and has generated over $2.4 million in delivery orders to date. A second large vehicle, IDC 4610122575 ($1.32 million ceiling awarded June 2025, through June 2030), established a streamlined procurement framework for wiring harnesses (NSN 6150-00-777-3068) with estimated annual demand of 1,477 units; three delivery orders totaling approximately $393,288 have been issued against this contract as of October 2025. Smaller IDCs with $250,000 ceilings include SPE4A622D5609 (May 2022–May 2024) for specialized cable assemblies, 4610110084 (March 2024–March 2029) for special purpose cable assemblies, 4610096896 (January 2023–January 2028) for cable assemblies and electrical components, and 4610085943 (January 2022–January 2027) for wiring harnesses. Barcar's top task-order vehicles by frequency are SPM45104D0623 (31 task orders, $835 thousand) and SP045104D0623 (29 task orders). The top five parent vehicles collectively account for roughly 121 task orders, demonstrating sustained engagement across the DLA Aviation procurement ecosystem.

Award category concentration reflects Barcar's manufacturing focus: the top five NAICS codes are Other Electronic Component Manufacturing (354 awards), Current-Carrying Wiring Device Manufacturing (188 awards), Electronic Connector Manufacturing (181 awards), Electric Power Distribution (63 awards), and Military Armored Vehicle, Tank, and Tank Component Manufacturing (33 awards). Top PSC codes show the same pattern — Miscellaneous Electric Power and Distribution Equipment (582 awards), Connectors, Electrical (204 awards), Miscellaneous Vehicular Components (168 awards), Cable/Cord/Wire Assemblies for Communication Equipment (87 awards), and Electric Vehicular Lights and Fixtures (58 awards).

Barcar maintains federal vendor registration dating to March 2002 and does not appear as a subcontractor in the source. The company operates 100% as a prime contractor across its recorded federal footprint. Combined potential value across all awards in the source totals $26.5 million; combined dollars obligated is $40.6 million, indicating that invoiced billings have exceeded contract ceilings — a signal of high utilization and frequent contract modifications or renewals. Recompete exposure in the next twenty-four months is minimal: only one award with ultimate completion within the window (combined potential value $22 thousand).