Detail Guide on Wire Harness Manufacturing Process

A wire harness, also known as a cable harness or wiring assembly, is a functional and well-organized arrangement of cables contained within an insulating material. The assembly’s purpose is to transfer a signal or electrical power. Wire harness production is a time-consuming, demanding, and task-oriented procedure. Wire harness is one of the most important electronic and electrical components today. There is a good no of wire harness manufacturers in India for all your wire harnessing needs. 

What is wire harnesses used for?

Wire harness is used for an array of purposes right from insulating wires to different applications for household and industrial purposes. They come in different shapes and sizes making day to day activities convenient and safe. The basic use of wire harnesses can be categorized into:

  1. Applications in the Automotive Industry – The transmission of electrical signals is part of a major wire system that enables automobiles to operate. I.e. as simple as turning on an automobile engine.
  2. Manufacturing – Wire harnesses enable connection and adequately encapsulate cabling and wires and make sure that production is completely maximized.
  3. Medical Applications – Medical devices’ wire harness applications must be long-lasting, customizable, and biocompatible like a defibrillator, pacemaker, or imaging apparatus, the gadget must be able to perform without fail on demand.
  4. Communication Systems – Wire harnesses play an important role in the construction of communication systems. A robust connection system involves an infrastructure capable of sending and receiving data in real-time anywhere on the planet.
  5. Military Equipment – Military equipment and weapons use a top-quality wire harness sustainable in harsh environmental conditions.

How is a wire harness manufactured?

The process begins with determining the purpose the harness is going to serve accordingly the design phase is executed. Using specialized equipment called a crimp centre, the wires are stripped and trimmed to the required lengths, and metal terminals are connected to the wires’ ends. The wires will then be put into a connector housing if necessary, allowing male and female wire bundles to be mated. Other wires stay outside of connectors and will be separately connected to the original equipment.

In the last phase, an assembly board is used to join the cables or wires with an outer covering that directs appropriate breakouts and enables final electrical testing. As routing wires or cables through sleeves is such a delicate procedure, human assembly is still the prevalent approach for wire harness fabrication. The following are examples of manual wire harness assembly operations:

  • Fabric tape is applied in various locations and quantities.
  • Crimping wire ends onto wires is usually a time taking task which can take several steps and need numerous crimping operations.
  • Putting one sleeve inside the other
  • Using clamps, cable ties, and tape to secure the strands

Different types of wire harness terminals

There is a no of different types of harness terminals according to the purpose they serve: 

Ring terminals – These are good for an easy attachment of screws and studs. The ring terminal ought to generally be viable with the wire check and stud size.

Spade Terminals – Are otherwise called spade connectors or fork terminals because of the state of the terminal. They facilitate fuss-free attachment and removal from the screw. A great choice for wire harness projects that have a space foundation for installation.

Flag Terminals – Flag terminals wonderful option for wire harness designs that must fit inside a certain amount of space and also when a quick disconnect is massive.

Butt Terminals – They connect or terminate one or more wires and protect the surface from erosion and tearing. This extra layer of defense keeps moisture, rust, and other harmful factors at bay. Because of its ability to connect and join wires.

Testing of harness

The growing need for faster, error-free wire harness manufacture has had an influence on every aspect of the process, thus testing has now become a crucial act, a computerized and efficiency-focused procedure that the end customer expects. Wire and wiring harnesses are subjected to a variety of testing. The electrical resistance of conductors is measured by investigations of the impact of the environment on wire insulation by ageing tests, electrical properties of wiring insulation measurements like electrical resistance, and durability.

Manufacturing process

Wire harness design – This is the first step involving the engineers ideating the wire design to best serve the purpose for which the wire is being made.

Prototyping – It is the process of ensuring optimal functioning in the version of the final product, where an engineer tests the harness in its specific applications before commencing the first production run.

Production and Assembly – Wire harnesses are highly specialized components that are intended to work with bigger parts. They are required to handle geometric and electrical challenges in the manufacture of items, as well as to give answers to specific problems that arise during the process.

Testing – It ensures each individual wire harness must undergo electrical safety testing.


Wire harnesses manufacturers give effective wiring solutions for electrical devices and equipment, which have a substantial impact on the goods’ overall performance, dependability, and stability. In every major industrial area, there is wire Harness Company in India that is therefore vital to the creation of correctly functioning goods. Right from the beginning to the final wire harness, design and assembly need meticulous preparation and a significant amount of physical labour. Each wire harness has a distinct role in integrating into a broader electronic network, making wire harnesses vital in today’s environment.

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