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Most automobile and construction machinery depend on cable assemblies for signal and power transmission. These cable harnesses feature a mass of cables bound by cable lacing, cable ties, straps, etc.
At Sierra Assembly, we specialize in providing precise and reliable cable and wire harness assembly solutions for a wide range of industrial applications. From automotive and aerospace to medical and power generation, our assemblies ensure organization, efficiency, and reliability in complex electrical systems.
Proper cable and harness assembly is essential to maintain the integrity of electrical systems. Bundling wires and cables into a single unit streamlines installation, reduces clutter, improves safety, and enhances performance.
A wire harness assembly is a collection of wires, cables, or subassemblies designed to transmit electrical signals or power efficiently. While a simple harness may consist of only a few wires, complex harness assemblies can include multiple wires, connectors, and both passive and active components.
Engineers and electrical contractors use cable harness assembly to keep wiring organized and maintain a tidy, functional layout. Typically, these assemblies are made from thermoplastic or thermoset materials to protect the wires from environmental factors such as heat, moisture, and abrasion.
A cable assembly consists of wires or cables bundled together and enclosed in a robust exterior material such as thermoplastic, thermoplastic rubber, or vinyl. While serving a similar organizational purpose as wire harnesses, cable assemblies are designed for harsher environments.
|
Feature |
Wire Harness Assembly |
Cable Assembly |
|
Purpose |
Organizes wires for safe and efficient installation |
Protects wires in harsh environments |
|
Materials |
Thermoplastic or thermoset sheaths |
Heavy-duty thermoplastic, vinyl, or rubber |
|
Applications |
Automotive interiors, electronics, industrial machinery |
Outdoor equipment, high-heat or high-friction environments |
|
Complexity |
Simple to moderately complex |
Typically, more robust and complex |
|
Benefit |
Cost-effective, organized wiring |
Enhanced protection and durability |
Design & Planning: Understand application requirements, including space, signals, and environmental conditions.
Wire Selection: Choose proper gauge, insulation, and type of wire for durability and performance.
Cutting & Stripping: Wires are cut to length and stripped for connection.
Connector Attachment: Attach terminals, pins, or connectors using crimping or soldering.
Bundling & Organization: Wires are grouped into harnesses using cable ties, lacing, or sleeves.
Assembly & Integration: Assemble into final configuration, ready for installation.
Testing & Quality Check: Inspect for continuity, insulation, and proper functionality.
Get your custom cable assembly services or wire harness solutions today. Our engineers will provide a detailed manufacturability review, cost estimate, and lead time tailored to your requirements. Request a Quote Now
|
Service |
Purpose |
Benefit to Clients |
|
Prototype Development |
Creating a functional prototype of the wire or cable harness before full-scale production. |
Helps test design, fit, and performance early to reduce errors and costs. |
|
Connector Tooling |
Preparing and installing specialized connectors for the harness assembly. |
Ensures reliable electrical connections and compliance with client specs. |
|
Wire Leads and Sets |
Cutting, stripping, and preparing individual wires and sets for assembly. |
Ensures consistent quality and simplifies final harness installation. |
|
Assembly Packaging |
Organizing and bundling wires and cables into a structured harness or assembly. |
Streamlines installation, reduces clutter, and improves safety. |
|
Printing on Heat Shrink |
Labeling wires, cables, or assemblies using heat shrink printing. |
Improves identification, traceability, and maintenance efficiency. |
|
Automated Wire Processing |
Using machines to cut, strip, and process wires for harness assembly. |
Increases accuracy, reduces labor, and improves assembly speed. |
|
Sonic Welding |
Joining wires or components using ultrasonic energy. |
Provides strong, reliable connections without solder, ideal for sensitive electronics. |
|
Installation and Testing |
Installing and testing harnesses to ensure proper connectivity and performance. |
Confirms every pcb assembly harness works as intended, reducing rework. |
|
Braiding and Harness Organization |
Using braiding, lacing, or ties to organize and protect wires. |
Enhances durability, reduces wear, and ensures a clean and safe harness. |
|
Problem |
Solution |
|
Wire damage due to friction or heat |
Use protective sheathing and high-quality thermoplastic/rubber materials |
|
Misaligned or incorrectly routed wires |
Implement precision design and automated wire processing |
|
Connector failure |
Use high-quality connectors and perform thorough testing |
|
Installation delays |
Provide pre-tested, organized cable wire harness assemblies ready for deployment |
|
Compliance issues |
Follow IPC, UL, ISO, and RoHS standards in design and assembly |
Automotive: Engine control, infotainment, lighting, safety sensors
Medical: Diagnostic devices, imaging, patient monitoring
Industrial: Heavy machinery, conveyors, control panels
Electronics: Computers, HVAC, communication devices
Alternative Energy: Solar inverters, EV wiring
Use our onlinePCB assembly cost calculator and quote PCB assembly online as per your specifications. Save your time with our PCB Assembly instant Online Quote.
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