Vertically Integrated Wire Harness Manufacturing

The first step in building any custom cable harness is to extrude a single conductor jacketed wire and then bundle it with other wires to form a multiconductor cable. Spooled wire can be stored until the rest of the assembly is ready to kit.

The process continues with injection molding where connectors are used on various types of electrical harnesses. Molten thermoplastic is forced into a mold and then allowed to cool, yielding the recognizable connector housing.

During assembly, optimized assembly processes are necessary to manage the complex steps required for the termination and assembly of various connector types. Process engineers work to streamline steps and add in-process job aides to help improve throughput and quality.

As far as overmolding is concerned, the overmolded connectors help provide an inexpensive and rugged means of strain-relieving custom cable assemblies. Other techniques, such as adding potting, epoxy, or ultrasonically welded housings, are options that designers can consider for high-volume builds.

The process concludes with testing where electrical tests are performed in process and again at the end of the assembly process. Usually, continuity testing alone is sufficient, but some applications demand more sophisticated and robust types of electrical testing.