Our wire harness assemblies are built to meet the highest industry standards in accordance with IPC/WHMA-A-620 standards and go through visual and electrical testing, including continuity, insulation resistance, and high-pot testing.
We are ISO 9001 certified, and we continuously invest in training, tooling, and process improvements to maintain consistency, traceability, and product excellence.
Combining multiple wires into one assembly, reduces system complexity and improves organization.
Protective sleeving and insulation safeguard the harness against mechanical wear and environmental factors, significantly extending the life of the electrical system.
By simplifying manufacturing and assembly wire harnesses reduce material waste, production cost and installation time.
Bundling wires together cuts down on clutter and helps keep the system neat and well-organized.
They minimize the risk of electrical hazards like shorts and fires.
We offer complete wire harness design and engineering services, supporting projects from concept through production. Our experienced engineering team works closely with clients to develop custom solutions that meet specific electrical, mechanical, and environmental requirements. Our design and engineering capabilities Include:
We specialize in producing high-quality, reliable wire harnesses built to meet your exact specifications. Our manufacturing process emphasizes precision, repeatability, and full compliance with industry standards, including IPC/WHMA-A-620 and ISO 9001. Our manufacturing capabilities include:
Every wire harness assembly goes through strict inspection and testing to ensure it works safely and reliably. Our inspection and testing capabilities include:
Wire harness assemblies and printed circuit board (PCB) assemblies are complementary components that work together to form integrated and reliable electronic systems. Their interdependence ensures consistent electrical connections, efficient system performance, and flexible designs.
Printed circuit boards form the structural and functional core of electronic systems, enabling circuit logic, signal processing, and control operations. They house and interconnect components such as resistors, capacitors, and ICs, and provide the internal circuitry for signal and power distribution.
Wire harness assemblies provide an organized and reliable connection between PCBs and other electronic or electromechanical components, enabling the transmission of power and signals throughout the system.
Wire Harness Assembly interdependence to PCB Assembly includes:
In applications ranging from automotive and aerospace to industrial automation and medical electronics, the seamless integration of PCB and wire harness assemblies is vital to the functionality, reliability, and maintainability of complex electronic systems.
The Schleuniger EcoCut 3300 can automatically cut all kinds of material including wire, cable, round material such as tubing, flat ribbon and Glass Fiber Optic (GOF) cable.
It processes wire up to 16 mm² (6 AWG), cuts round material up to 12 mm (0.47") O.D. and cuts flat material up to 100 mm (3.94") wide.
Flat Cables
Round cables, profile
Shrink Tubing
Thin metallic, nonmetallic sheets
Tubing
Wire marking
Woven fabric
The Schleuniger Strip Series B300 stripping machine performs reliable stripping of cables with cross sections from 0.03 to 8 mm2 (32 to 8 AWG).
Discrete Wire Processing
Full Strip
Multiconductor Cable Stripping
Partial Strip
The Schleuniger MultiStrip 9480 is a high-performance, fully automatic wire cutting and stripping machine designed for precision and versatility for a variety of wire harness applications.
Cut to length
Full or partial strip left and right
Jacket and inner conductor stripping
Jacket stripping of extremely thin insulations
Jacket stripping of multiconductor cables
Multilayer stripping
Multilayer with shield processing (coax, hybrid, etc.)
Multistep jacket stripping with inner conductor stripping and
window slitting
Multistep stripping
Trimming, separating and stripping of individual zipcord
conductors
Wire marking
The Schleuniger CT 60 is a pneumatic benchtop crimping machine engineered for high-force, loose-piece crimping applications. It delivers up to 60 kN (6.7 tons) of parallel crimping force, making it suitable for processing a wide range of terminal types and wire sizes.
The quality of the crimp is guaranteed by a full-cycle mechanism that assures that the dies have closed completely before they are reopened.
The Schleuniger UniCrimp 208 is a high-performance benchtop crimping machine designed for precise and efficient crimping of rear-feed and side-feed banded terminals. With a crimping force of 33 kN (3.3 tons), it accommodates a wide range of wire sizes and terminal types, making it ideal for various wire harness assembly applications.
Discrete wire crimping
Multiconductor cable crimping
The Schleuniger StripCrimp 208 stripping machine combines the standard working processes of cable processing in a single machine. Short breakout lengths of 22 mm (0.86") and even down to 10 mm (0.39") using special tools permit the processing of sensor applications.
Discrete wire crimping
Discrete wire stripping
Discrete wire stripping & crimping
Multiconductor cable crimping
Multiconductor cable stripping
Multiconductor cable stripping & crimping
Multistep stripping
The semiautomatic Schleuniger CoaxStrip 6480 stripping machine processes coaxial cables with an outer diameter of 1.2 to 12 millimeters.
It is equipped with "cable end detection" and "cable diameter verification."
The WTT Wire Terminal Pull Tester is designed to test the pull-out force of crimped wire terminals. It features a digital display for accurate force measurement and can be used for quality control in wire harness production.
The tester helps ensure that crimped connections meet required specifications and industry standards for pull-out strength.
Wires and Cables The core elements that carry electrical signals or power. Typically made of copper or aluminum, with various insulation types (PVC, Teflon, etc.).
Grommets and Seals Used where wires pass through panels or bulkheads. Provide environmental sealing and protect from sharp edges.
Connectors Devices that join wires to other components or systems. Can be standard or custom, and include plug, socket, or multi-pin types.
Ties, Clamps, and Fasteners Organize and secure wires in place. Include zip ties, cable clamps, and adhesive mounts.
Terminals Metal ends crimped or soldered onto wires for secure electrical connection. Types include ring, spade, blade, and bullet terminals.
Labels and Markers For wire identification, assembly tracking, and installation guidance. Types include heat-shrink labels, barcode tags, and laser-etched markers.
Insulation and Sleeving Protects wires from abrasion, heat, moisture, and chemicals. Includes materials like heat-shrink tubing, PVC sleeves, and braided sheaths.
Tapes and Wraps Used for bundling wires and adding abrasion resistance. Include cloth tape, electrical tape, and spiral wraps.
Strain Reliefs Prevent wires from bending or pulling at connection points. Helps extend harness life and maintain connection integrity.
Protective Jackets An outer covering that bundles the harness and adds extra protection. Common in automotive, aerospace, and military applications.
Wire harness manufacturing is a structured, quality-driven process that ensures safe and efficient routing of electrical power and signals in a wide variety of applications.
Create a reliable, manufacturable blueprint that meets all functional and safety specs.
Ensure all components are compatible and meet the operating requirements (temperature, vibration, moisture, etc.).
Achieve clean, consistent wire preparation for reliable terminations.
Create secure, conductive, and durable connections.
Assemble interconnect points that meet design intent and environmental requirements.
Ensure the physical layout fits into the final product and protects wires from wear.
Support easy installation, maintenance, and traceability.
Guarantee safety, function, and compliance with IPC/WHMA-A-620 standards.
Electrical tests include:
Deliver ready-to-install wire harnesses that are damage-free and production-ready.
Quality Management System We adhere to a formal quality management system, such as ISO 9001:2015.
Compliance with Industry Standar Our wire harness assemblies are manufactured in accordance with IPC/WHMA-A-620 standards.
First Article and In-Process Testing We conduct thorough first article inspections and in-process testing, including automated pull testing for crimps, to verify the integrity of each assembly.
Final Testing Utilizing advanced testing equipment, we perform comprehensive evaluations to detect opens, shorts, mis-wires, and other potential issues, ensuring each harness meets specified thresholds.
Continuous Improvement Our quality system is regularly monitored, measured, evaluated, and enhanced to meet or exceed customer expectations, ensuring the highest performance and reliable solutions.
Wire harness assemblies deliver dependable power and signal distribution for machinery, robotics, automation systems, and control panels. They are built for durability, resistance to harsh environments, and long service life.
Wire harness assemblies ensure reliable power and signal distribution for avionics, communication, navigation, engine control, and safety systems. They are engineered for lightweight design, durability, and resistance to extreme environmental conditions.
Wire harness assemblies provide compact, organized, and reliable connections for devices such as computers, appliances, gaming systems, and smart devices. They enable efficient signal transmission and power distribution while supporting sleek designs and high-volume production
Wire harnesses are essential in modern vehicles. They connect critical systems such as engine control units, lighting, infotainment, safety features (airbags, ABS, ADAS), climate control, and sensor networks. They reduce wiring complexity, improve reliability, and support modern automotive technologies.
Wire harness assembly provides reliable connectivity for imaging systems, diagnostic equipment, patient monitoring, and surgical instruments. They are designed for high precision, biocompatibility, and compliance with strict safety and regulatory standards.
A wire harness is an organized assembly of wires, cables, connectors, and terminals that transmits electrical power and signals between components within a system.
A wire harness groups multiple wires into a structured bundle, often with protective sheathing or coverings, while a cable assembly usually refers to a single cable or fewer conductors with connectors attached.
Wire harness assemblies are widely used in automotive, aerospace, medical devices, industrial equipment, telecommunications, and consumer electronics.
Materials typically include copper wires, insulation, terminals, connectors, protective sleeving, heat-shrink tubing, and labeling for identification.
Harnesses undergo 100% testing, including visual inspection, continuity testing, insulation resistance checks, and sometimes high-pot or functional testing, to ensure quality and compliance with standards such as IPC/WHMA-A-620.
Wire harness assemblies reduce assembly time, improve reliability, minimize wiring errors, simplify maintenance, and enhance mechanical protection.
Yes. Wire harnesses are tailored to the specific requirements of each application, including wire type, length, connector choice, labeling, shielding, and routing.
Lead time depends on complexity, volume, and component availability. Simple harnesses may take days, while complex or high-volume builds may require weeks.
By organizing and protecting wires, harnesses reduce the risk of short circuits, abrasion, loose connections, and overheating, ensuring safe and reliable operation.
A wire is a single, flexible strand or rod of metal—most commonly copper or aluminum—that conducts electricity or transmits signals.
A cable is an assembly of two or more insulated wires bundled together within a protective outer jacket. Unlike a single wire, which only carries one electrical path, a cable groups multiple conductors to transmit power, signals, or data in a more organized and protected way.
A group of organized wires and components designed to route power and signals.
Similar to a wire harness but often covered with a single outer jacket for added protection.
A connector is an electromechanical device used to join electrical circuits together, allowing the transfer of power, signals, or data between two or more components.
A terminal is a conductive end-point used to connect a wire to another wire, a connector, or a c rovides a reliable interface for electrical connection without needing a permanent solder joint.
A contact is the conductive element inside a connector that physically touches another conductive surface to complete an electrical circuit. It provides the actual electrical interface between two mating connectors male pin and female socket.
A pin is the male conductive part of a connector that fits into a corresponding female contact or socket to complete an electrical circuit. It transfers power or signals by making contact with the female socket
A socket is the female part of a connector designed to receive a pin (male contact) to complete an electrical connection. It provides a secure receptacle for the pin, ensuring reliable transfer of power or signals.
Crimping is the process of mechanically attaching a terminal or connector to the end of a wire by deforming the metal to create a secure electrical and mechanical connection. It provides a reliable, low-resistance electrical connection without having to solder.
Soldering is the process of joining a wire to a terminal, component, or connector by melting a filler metal (solder) to create a strong electrical and mechanical bond.
Stripping is the process of removing the insulation from the end of a wire to expose the conductor, preparing it for termination, crimping, or soldering. It exposes bare wire so it can make a reliable electrical connection.
Twisting is the process of spiraling two or more wires together to form a single, organized bundle, often used to reduce electromagnetic interference (EMI) and improve signal integrity.
Tinning is the process of coating a wire or a terminal with a thin layer of solder before making a final connection. It improves solderability by making it easier to form a strong bond, it prevents oxidation of the wire or terminal and it ensures consistent electrical conductivity.
Sleeving is the process of covering wires or wire bundles with a protective tube or sheath to organize, protect, and insulate them. It protects wires from abrasion, heat, chemicals, and moisture and provides electrical insulation in certain applications.
Heat shrink is a tubing or sleeve that shrinks when heated to tightly cover wires, terminals, or wire bundles, providing insulation, protection, and strain relief.
A Zip tie is a plastic strap used to bundle and secure wires or cables together.
A grommet is a protective ring or sleeve inserted into a hole in a panel, enclosure, or bulkhead to shield wires, cables, or hoses passing through it. It protects wires or cables from abrasion, sharp edges, or vibration, helps seal openings against dust, moisture, or chemicals and it provides strain relief where wires pass through panels.
A loom or conduit is a tubular protective covering used to organize, bundle, and shield wires or cables in a wire harness from physical damage and environmental hazards. It protects wires from abrasion, moisture, heat, chemicals, and mechanical stress.
A continuity test is a basic electrical test used to verify that an electrical path exists between two points in a wire, cable, or circuit. It confirms that wires or connections are intact and unbroken. It detects open circuits or breaks in a wire or harness.
A Hi-Pot test (short for high potential test) is an electrical test used to verify the insulation strength of wires, cables, or components by applying a high voltage between conductors or between a conductor and ground. It detects shorts, leakage paths, or weak insulation.
A pull test is a mechanical test used to verify the strength and security of a wire, terminal, or connector crimp by applying a controlled pulling force. It confirms that a crimped or soldered connection can withstand mechanical stress without failing.
IPC/WHMA-A-620 is an industry standard for the requirements and acceptance criteria of cable and wire harness assemblies.
CAD in wire harness design refers to the use of CAD software to create, visualize, and document wire harness layouts and assemblies. It is used to design precise wire routing, connector placement, and harness geometry. It helps plan for mechanical constraints, electrical requirements, and assembly feasibility.
A formboard in wire harness assembly is a physical or digital template used to lay out wires, connectors, and components in the correct positions and lengths before final assembly. It ensures accurate wire routing and proper lengths. It serves as a guide for assembling complex harnesses. It helps prevent errors, tangling, and misalignment.
A wire list in wire harness design and assembly is a detailed document that specifies every wire in a harness, including its type, length, color, gauge, and termination points.
A BOM is a comprehensive list of all components, materials, and parts required to build a wire harness. It provides a complete reference for purchasing, assembly, and quality control. It ensures that every wire, connector, terminal, sleeve, and protective component is accounted for. It helps plan production, inventory, and cost estimation.
