Assembly Services
Custom Wire Harness
- Circuit-dependent; up to 200 °C and 1000 V with the right wire
- 1 to 60 positions, single or double ended
Wire Harness Assembly Services
Cut-strip-crimp leads, over-moulded and potted assemblies, and the general build-to-drawing service that sits behind every other harness line.
3harness lines
7application groups
Not every requirement is a finished harness. Sometimes it is a lead, an over-moulded assembly, or a build-to-drawing service applied to a part that is almost a harness. This group collects the work that sits underneath the application harnesses and supports them.
The common thread is process control on a joint. Whether the joint is a crimp barrel, a solder pot or a moulded body, it is either inside the specification the terminal or the compound maker published or it is a future field failure — and the difference is measurable rather than a matter of opinion.
Cut, strip and crimp is the volume end. The work is sized from 6 AWG down to 28 AWG, cut to length with a tolerance taken from the drawing, stripped to a length that suits the terminal rather than to a nominal, and then either crimped or tinned. Tinning is not a substitute for a crimp: a tinned conductor is for a screw clamp or a solder cup, while a crimped barrel is a cold weld between conductor and terminal and should never be pre-tinned before crimping.
Over-moulding and potting is the other end. The compound is chosen for the wire it has to bond to and for the environment it has to survive, because a moulding that grips PVC well may not grip a fluoropolymer at all, and a body that sets hard at low temperature will crack at the cable entry. Strain relief is designed at the same time as the mould, and it is the entry geometry that sets the ingress rating.
Everything in this group is quoted as a build-to-drawing service, which means one supplier, one lot record and one point of contact for the programme. A single set for fit and function is normally the first deliverable: hand tools, no committed tooling, and a written confirmation of the wire line, the terminal series and the connector before the volume run starts. Tooling is committed only once the design stops moving.
Assembly Services harness lines
Each line states the wire it is built on, the conductor range, the termination style and the inspection method.
Assembly Services
Terminal & Crimped Wire Leads
- Follows the wire selected; 30 V to 600 V, 80 °C to 200 °C
- Single lead to multi-leg assemblies with 2 to 30 terminations
Assembly Services
Over-Moulded & Potted Cable Assembly
- Follows the wire; up to 105 °C moulding compounds
- 1 to 20 circuits; single, split and daisy-chained mouldings
Other harness application groups
Assembly Services harness questions
What buyers ask before they send a drawing for this group.
Can the cut, strip and crimp work be taken on without a full harness?
Yes. Loose leads, single-ended leads and pre-terminated jumpers are all quoted from a schedule of lengths, wire lines and terminal part numbers, with no harness drawing needed. It is the right route when the customer has assembly capability in house and wants conductor preparation taken off the line.
How is a crimp proved to be inside specification?
By measuring it rather than by looking at it. The crimp height is checked against the terminal maker’s published range with a micrometer or a crimp-height gauge, the pull-test value is recorded against the lot, and the tool is the one specified for that terminal series. A visual check confirms that the wrong terminal was not used; it does not confirm that the joint is inside specification.
Do you supply loose leads as well as complete harnesses?
Yes, and the two are usually quoted together. A programme often starts with leads and moves to harnesses once the assembly moves in house or the volume justifies it. The wire line and the terminal series stay the same across both, so the transition does not require the design to be revalidated.
Request a wire harness quotation
Tell us the style, AWG, colour and quantity — or attach nothing and just describe the requirement. We reply to every enquiry.