Cable and wire harness manufacturing is the process of designing and producing bundled electrical wiring systems that connect different components in your device. Harnesses ensure reliable power and signal transmission, reduce assembly time, and improve organization within enclosures or machinery.
What is a Wire Harness?
A wire harness is a structured assembly of cables, connectors, and protective coverings that route power and data between components. Unlike loose wiring, harnesses are pre-assembled to exact specifications, making production more efficient and reducing installation errors.
Essential Factors to Consider
- Wire Type – Gauge, insulation, and conductor material must match current requirements and environmental conditions.
- Connectors – Proper mating connectors (Molex, JST, TE Connectivity, custom) are critical for reliability.
- Shielding & EMI Protection – Especially important in sensitive embedded systems.
- Protective Coverings – Heat-shrink tubing, braided sleeving, or overmolding for durability and safety.
- Standards & Certifications – Look for IPC/WHMA-A-620 compliance, ISO certifications, or industry-specific (UL, automotive, medical).
How to Choose the Right Manufacturer
- Customization: Ensure the vendor can build to your drawings (schematics, pinouts) and offer prototyping.
- Volume Flexibility: Some vendors excel at small custom runs, others at large-scale production.
- Testing Capabilities: Good harness manufacturers perform continuity, Hi-Pot, and functional testing.
- Material Sourcing: Check if they provide turnkey solutions (wires, connectors, sleeving) or require you to supply parts.
- Communication & Documentation: Proper drawings, labels, and revisions prevent costly mistakes.
Typical Price Points
Prices depend heavily on complexity, wire length, connector type, and volume:
- Simple harnesses (few wires, basic connectors): $5–$20 each in small batches.
- Medium complexity (10–20 wires, shielding, mixed connectors): $20–$80 each.
- High-complexity/custom assemblies (multi-branch harnesses, automotive/medical spec): $100+ each.
Tip: Costs drop significantly in volume, but upfront setup and tooling for crimping/overmolding may add one-time fees.
Finding the Best Fit
- For prototypes: use local harness shops or quick-turn custom cable services.
- For low-mid volumes: regional vendors balance cost and communication.
- For mass production: overseas suppliers (China, Mexico, Eastern Europe) provide cost advantages, but ensure testing standards are met.