MarVac Assemblies is equipped with wire processing equipment suited for all types of insulated wire. We can work with 1 to 26 AWG solid or stranded wire, and our services meet WHMA/IPC-A-620 industry standards. Our custom wire harnesses and cable assemblies are ideal for a broad range of industrial and commercial applications.

Learn more about our custom wire harness and cable assembly capabilities, our process, common applications for our products, and more.


How Do Custom Wire Harnesses and Cable Assemblies Differ?

Many people refer to custom wire harnesses and cable assemblies interchangeably. While they share similar functions, there is an important difference.

Custom Wire Harnesses

A custom wire harness has numerous electrical wires branching off in various directions, with each branch having multiple terminations. The wires are visibly separate, and it’s possible to remove the individual wires. A custom wiring harness is a cost-effective, efficient solution for organizing wires and cables. Wire harnesses also simplify installation, allowing technicians to easily install a single component containing all necessary wire or cable subassemblies.

Custom wiring harnesses also fulfill several design functions.

  • Protection: Although custom wire harnesses cannot protect against the effects of friction between harnesses or extreme temperatures, the completed assembly is somewhat protected from abrasions and vibration. More importantly, a wire harness protects external components and users from electric shock.
  • Purpose: The main purpose of a custom wiring harness is to route wires and cables more efficiently. It also saves space in an assembly and streamlines the installation process.

Cable Assemblies

A cable assembly is much simpler, consisting of multiple extruded wires in a single sheathe-like jacket and having just two separate terminal ends. Cable assemblies support the same “drop-in” installation described above but with more protection for the wires.

  • Protection: Compared to wire harnesses, cable assemblies provide greater protection from temperature extremes, moisture, dust, friction, and corrosion. This makes a cable assembly ideal for outdoor applications.
  • Purpose: In addition to protecting the wires from damage due to harsh environmental conditions, cable assemblies protect outer components from electric currents while organizing wires for easy installation.


Custom Wire Harness & Cable Assembly Applications

MarVac Assemblies’ custom wiring harnesses and cable assemblies support a broad variety of products and technologies, including:

  • Electrical system assemblies
  • Heaters
  • Lighting fixtures
  • Off-road vehicles
  • Power supplies
  • Printed circuit boards
  • Refrigeration equipment
  • Welders

We also support a wide range of custom wire processing services, such as cutting, marking, stripping/retaining, crimping, twisting, and terminating ends. See the chart below for more information.

Custom Wire Harness Assembly Capabilities

  • Custom Wire Harness Applications: Custom wiring harnesses are integral to many household products, tools, washing machines, refrigerators, and other consumer appliances. Almost every automobile, airplane, and other vehicle uses custom wire assemblies. They’re also a mainstay in various electronic devices, construction machinery, and industrial equipment.
  • Cable Assembly Applications: Cable assemblies are best suited for wire applications involving extreme temperature fluctuations and other harsh environmental conditions.


Component Modification Capabilities

MarVac Assemblies can ship our custom wire solutions to the customer or install them in finished assemblies at our facility. Our technicians carefully evaluate customer project requirements, provide accurate quotes, build prints and specs, test each component for quality, and more.

Our wire harness component modification capabilities extend to the following components and products:

  • Chokes, Inductors, and Ferrites
  • Capacitors
  • Fans and Blowers
  • Fuse Holders, Circuit Protection
  • Relays and Timers
  • Resistors and Potentiometers
  • Indicator Light Assembly
  • Lighted Switches/Lamps
  • Sensors
  • Solenoids
  • Switches
  • Terminal Blocks


UL Recognized Custom Wire Harness & Cable Assembly Capabilities

Our UL-recognized custom wire harness and cable assembly capabilities include:

  • Modular – Phone, Cat5, Serial Cables
  • Multi-Conductor
  • Ribbon Cable
  • Single Lead
  • Ultrasonic Welding
  • Harnessing
  • Laser and Hot Stamp Marking
  • Twisted Pairs
  • Terminating
  • Soldering


Custom Wire Harness Assembly Process

Here’s an overview of our custom wire harness assembly process:

  • Wire Cutting: We begin by cutting wires to the proper length using a cutting machine.
  • Stripping: A stripping machine exposes the wire cores and identifies each wire.
  • Connections: We then match the wire terminals, modules, or connector housings.
  • Assembly: Lastly, we use an assembly board or workbench to gather the wires into the harness per the design specifications. This involves putting the wires and subassemblies on the assembly board, routing them through any sleeves, and applying tapes, ties, or wraps on branch-outs. The wire harness is then ready for crimping terminals and soldering wire ends using a solder machine.
  • Testing: After assembly, we test each wire harness to ensure 100% reliability and safety.


Cable Assembly Process

As a UL-recognized cable processor, MarVac Assemblies exclusively uses factory tooling for most major connector manufacturers, including but not limited to:

  • AMP
  • Amphenol
  • Delphi
  • Hirose
  • JST
  • Molex
  • Packard

By default, we provide 100% continuity testing on multiple conductors, and we offer further testing services upon request.


Custom Wire Harness & Cable Assembly from MarVac Assemblies

MarVac Assemblies manufactures a wide array of harness configurations, such as single lead, multi-conductor, ribbon cable, twisted pairs, and more. We offer the highest-quality, bench-top box-build subassembly wire processing. This includes component preparation, harness production, soldering, testing, kitting, and custom packaging.

Request more information or contact us today to learn more about our suite of custom wire harness and cable assembly services.