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Wire Harness Manufacturing Process Explained in Brief

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Apr 27,2022

A wire harness is a term for cable and wire harness assembly, which is used for signal and power transmission in various applications. A reliable and durable material like vinyl, electrical tape, etc., is used to bundle the cables. Wire harnesses are used in automobiles, flat panel displays, flight simulators, ruggedized computers, heavy equipment, and so on. The wire harness manufacturing process differs according to its designs and work requirements. As the demand for wire harnesses grows, it is important to understand the wire harness manufacturing process in detail. This post offers insights into this process and more.

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The wire harness manufacturing process can be simple to complex, depending on the design. The following are a few common steps involved.

Automated machinery is used at minimal levels during all these processes.

  • Design:

    Like any other electronics manufacturing, the manufacturing process of wire harnesses always begins with an appropriate design. They can be found anywhere – behind an automobile glove box or in the panel of industrial machinery or washing machine. They deliver data and power in a streamlined way. The designs would vary across these applications. So, creating a custom design is one of the challenging aspects of the wire harness manufacturing process. In this stage, the design engineers also need to address the performance issues the wire harnesses may encounter during the regular operation. In addition to this, they also need to fix components, as well as decide on components, materials, and other aspects.

  • Prototyping:

    It is always beneficial to have a functional prototype of a wire harness to eliminate further downtime. This helps an engineer or product engineer understand how the wire harness will work in a real-time environment.

  • Production and Assembly:

    The wire harness manufacturing process is largely manual, unlike other electronic manufacturing processes. These assemblies often work as components for large parts. It is because wire harnesses require a high level of customization. Manual assembly helps resolve electric and geometric issues associated with the manufacturing of certain complex products. The following are a few important steps involved in the wire harness manufacturing process:

  • Wire Cutting:

    In this step, the wires are cut to the required length using a wire-cutting machine.

  • Stripping and Connections:

    In this step, the wires are stripped to attach connector modules, housings, or terminals.

  • Assembly:

    In this step, the wires are harnessed using an assembly board.

  • Testing:

    Safety testing is an essential aspect of any electronics manufacturing project. In this phase, the wire harnesses are tested rigorously to check their utility and sustenance in real environments.

If you are looking for custom wire harnesses for your application, it is important to partner with trusted manufacturing services such as Creative Hi-Tech. The company provides wire harnesses in custom specifications to meet your application requirements. It also specializes in custom printed circuit board assembly and manufacturing. You can visit https://www.creativehitech.com to know more about wire harness manufacturing capabilities of Creative Hi-Tech.

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