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A wire harness is a collective term for a systematic set of wires organized together with terminals and connectors within a thermoplastic insulating material. Generally, these devices protect and organize wires, making them safer and easy to navigate simultaneously.

This article will discuss the importance of wire harnesses, the processes involved in custom wiring harness manufacturing, and their value to different industries.

Importance of Wire Harnesses in Electronics

Wire harnesses are crucial components of electronics. It serves as the backbone of digital parts, allowing the transmission of electronic signals from one point to another. Instead of multiple cables running in a parallel circuit, wire harnesses provide a safer option featuring a centralized connection.

Here are some major benefits of the wire harness in an electrical assembly.

  • Protects wires from heat damage and increases their lifespan
  • Seamlessly connects digital components
  • Promotes better airflow within the electrical assembly and the chassis
  • Helps minimize electric shocks
  • Fosters a more organized working environment for wiring engineers
  • Protects wiring systems from dust and debris

Processes Involved in Custom Wiring Harness Manufacturing

Depending on the design, wire harnesses can be manufactured in different ways. However, it all begins with design and prototyping. Engineers develop custom wiring designs and prototypes before the actual manufacturing process to deliver power or data efficiently. The process eliminates possible risks, makes it easier to decide on the components and materials, and allows future-proof wiring solutions in areas that may require it.

Most of the manufacturing processes are done in the production and assembly stages. Here, components for large parts requiring high customization levels are assembled manually since manual assemblies make it easier to address possible geometric issues in the wire harness.

Below are the next steps involved in the wire harness manufacturing process:


Crimping is a necessary manufacturing process in wire harness production. It is the process of joining pieces of metal by deforming one or both components to hold each other inside the harness. The process allows connecting a terminal to a wire conductor without having to undergo soldering, reducing the risk of corrosion.


In this step, wires are cut to size depending on the initial design or prototype of the wire harness assembly. A wire-cutting machine is utilized to standardize the process.


Coiling makes it possible to keep long wires together and intact. It also aids in minimizing stress on the wire by providing allowances for movement, such as bending and stretching.


Inserting the wire into the connector after crimping contacts to the end of the wire is part of the connecting process.

Sub-Assembly Integration

In the sub-assembly stage, build components are integrated into different component assemblies to create a large segment of the final product. Manufacturing sub-assemblies makes it easier to assemble the final product, which saves time and resources for OEMs.


Soldering is joining different wires and sub-assemblies with a metal alloy to create a larger end product or component.


Removing the outer protective sheet of the wire harness without cutting the components beneath describes the stripping process. Stripping enables the electrician to expose the wire to create new connections or to do repairs.

Terminal Application

In the terminal application, the wire harness is connected to the junction connector, which functions as a wire connector. The terminal serves as the connection between the plug and the wire. In the automotive industry, terminal crimping is the link in the production process of automotive wire harnesses.

Ultrasonic Wire Welding

Ultrasonic wire welding is the technology used in creating wire harnesses in different industries and is the ideal welding type for connecting plastics and metals. It is the process of combining multiple wires to a terminal or conductive contact material. The connection is achieved with high-frequency ultrasonic vibrations applied to the components to create a solid weld.

Industry Applications of Wire Harnesses

Wire harnesses are indispensable components in residential, commercial, and industrial settings. Here are some of the major industries benefiting from wire harnesses:


Wire harnesses enable transmitting signals and commands from the main terminal to power up engines. They also connect the engine to the vehicle’s other functions, such as brakes, audio, HVAC, and lighting.


Wire harnesses connect a device to its power and signal system to allow it to function and perform efficiently.


Wire harnesses protect wiring used in imaging, radiology, and pacemakers. These components are essential to keep these devices running optimally, preventing catastrophic medical or health problems.


Telecommunications networks operate and communicate through wires protected and bolstered by wire harness technologies.

Consumer Electronics

Multiple wire harnesses are the backbone of all consumer electronic products. From small appliances to supercomputers, wire harnesses make it possible to transport data and power various gadgets and devices.

Custom Wire Harness Solutions From MarVac Assemblies

If you are looking for reliable and high-quality wire harness solutions for your data and electrical needs, look no further than MarVac Assemblies! Our IPC/WHMA-A-620 Certification Program sets us apart from the competition, and we offer unmatched flexibility and expertise in turnkey solutions for electrical assembly.

Learn more about our products and services when you contact us today!

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