Custom Electrical Wiring Harness Manufacturer

Data Cable is a world class manufacturer of custom cable assemblies, wire harnessing, electro-mechanical assemblies and other interconnect solutions for a widely diverse group of industries – defence, medical, robotics, UAVs, transportation, industrial equipment, satellite & communications, nuclear & power, agriculture, forestry, mining & more.

Since 1980, Data Cable has enjoyed sustainable growth and success. We value the excellent reputation we’ve earned for quality, competitive pricing, and customer service.

For companies that make machinery, equipment or electrical control panels with a number of wires and cables, it can be very time consuming to route and terminate the wires and cables one by one. The most common solution is to make these wires and cables outside the equipment and then bundle them together into the form that best fits inside or on the machine. The result is an electrical wiring harness.

An electrical wiring harness that consists solely of wires is typically called a wire harness. However, with increased and complex requirements, these harnesses often include not just the wires but also cables for networking, position feedback, shielded power, and other functions. In such cases, the term electrical wire harness provides a more accurate description.

Once the harnesses have been electrically completed, the bundles can be tie wrapped, taped, braided, covered in sleeving/spiral wrap, or any combination of these to make it an integrated assembly.

Electrical wiring harness manufacturers need to be capable of much more than the termination of copper wire. They must also be able to build cable assemblies with complex connectors and shielding requirements, and potentially have access to fiber optic assemblies that may also be incorporated into the design.

Why would an equipment manufacturer take the time to layout or design a harness as a separate sub-assembly?

If they’re making more than one or two machines of the same design, using a harness will increase the throughput by significantly reducing the time the machine sits in inventory while the wiring is being completed.
The electrical wiring harness is thoroughly tested prior to arriving at the machine, which minimizes the need for trouble-shooting due to uncaught, crossed, or missing connections.
Reliability is improved as the electrical wiring harness is assembled using processes that are more consistent and predictable than manually terminating wires with a hand tool.

Making custom wire harnesses on a repetitive basis, with a dependable process, requires a great deal of special equipment, tooling, test equipment, and skilled assemblers. A typical custom wire harness assembly can have a large number of components, parts, and many different types of wires. All of these reasons make outsourcing a custom wiring harness manufacturer an ideal option for OEMs of specialty-made equipment. While the setup can be extensive, once completed, it will yield consistent results.

If you are looking for a custom wiring harness manufacturer, contact the team at Data Cable.