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Custom Cable Assembly & Wire Harness

Shenzhen Jinhuicheng Technology: a Professional Custom Cable Assembly & Wire Harness Manufacturer

We can not only provide high-quality products and competitive prices, but also ensure fast delivery time and good after-sales service.
Variety of Products
We mainly research and produce customized cable assemblies, such as coaxial cables, control cables, connecting wires, XLPE cables, cables and other customized special cables. We can also provide LCD LED panel connection cables, wiring harnesses, power cables, coaxial cables, FFC FPC cables, and waterproof cables,There are lots china wiring harness custom manufacturers,but we are the most flexible one.

Advanced Production Equipment
We have 10 sets of domestic first-class plastic extrusion production lines and three-layer co-extrusion foaming machines. We are also equipped with an online detection system that can monitor and adjust the capacitance, outer diameter, and eccentricity of the cable to ensure the high quality of the cable.

Multiple Professional Certifications
We have a complete quality assurance system, and our products comply with CCC (China Compulsory Certification), US UL certification, ISO9001, and ETL certification. Our raw materials comply with RoHS, REACH and SGS standards.

OEM ODM Available
Our company has 18 years of manufacturing experience. At the same time, we are an OEM and ODM china custom wiring harness factory for many well-known brands around the world, such as ASUS, Sceptre, DELL, KONKA, LG, VIZIO, etc. We can also manufacture products according to your design.

Brief Introduction to Custom Cable Assembly & Wire Harness

Cable assemblies are a group of wires or cables covered by a much more intensive exterior product. In general, they are made from heavy-duty materials, including shrink-wrapped thermoplastic, thermoplastic rubber, or vinyl. These assemblies serve a similar function to wire harnesses, including keeping wires and cables organized, but are designed for entirely different environments. A wire harness, also known as a cable harness or wiring assembly, is a grouping of wires, cables, or subassemblies designed to transmit signals or electrical power. A basic Wire Harness may include as few as three discreet components, while the more classic harnesses include many more wires and other passive, and potentially active, components. A wire harness is often confused with a cable assembly; the main difference between the two is that a cable assembly usually has just two ends while a wire harness has multiple branches/ends running off in many different directions with multiple terminations on each branch.

Cable Assembly & Wire Harness:Features,Uses,and Types

Cable Assembly
1.Features of Cable Assembly
A typical cable assembly usually includes wires or cables (for electrical or signal transmission), connectors at the cable ends, and a form of insulation to safeguard the cables against moisture or heat and for health and safety reasons. A sheath or jacket envelops the entire assembly, which provides an additional layer of protection. Wire color coding is also usually used to help with wire identification. Cable assemblies are made following some general steps. First, wires are cut to the desired length using specialized wire-cutting machines. Then, the wire ends are stripped to expose their cores. Next, the wires are fitted to the required terminals or connector housings, each with distinct sizes and specifications. Finally, the wires are assembled into a harness, using a workbench or assembly board configured to adhere to design specifications. Wire assemblies can either be made by hand or by machine. Each method requires a series of steps, or processes, to achieve the desired cable assembly. This includes routing and then inserting wires through sleeves, crimping terminals, taping wires, and fastening strands with clamps, tape, or cable ties.

2.Uses of Cable Assembly
Cable assemblies have a wide range of uses in different industries. They are used anywhere where a group of cables are needed for a single connection. These assemblies can be used to transmit either electricity or signal. Some of their common uses include: flat panel displays, navigation systems, computers, telecommunication applications, LEDs, electronics, drones, automobiles, airplanes, and more. Cable assemblies are typically used whenever electronic hardware is involved. They serve three primary functions. Firstly, they protect technicians and contractors by encasing the wiring bundle in a durable sheath made of materials like shrink-wrapped thermoplastic, rubber, or vinyl. This safeguards against potential hazards from electrical currents, ensuring the safety of bystanders. Secondly, wire harnesses within cable assemblies facilitate easy navigation of electrical systems, maintaining a highly organized wiring configuration. Lastly, cable assemblies act as a protective barrier for the wires and cables within their sheaths, shielding them from wear and tear, harsh environmental conditions, and other incidental damage.

3.Common Types of Cable Assembly
There are many different cable assembly types. Some common ones are discussed below:
*Molded Cable Assemblies
Molded cable assemblies, or overmolds, have their connectors and wires combined into a single component. The cable assembly is put into a mold, and molten plastic is then injected into the mold cavity. It is then allowed to cool and turn solid. The result is an encapsulated junction of the wire and connector. Some of the benefits of this type of assembly include: good flexural strength at the spot at which most of the connector and cable movements take place, and good resistance against shock, impact, and abrasion. This design can incorporate a waterproof element, and it also helps with installation. Molded cable assemblies are used in applications that require a more finished and durable appearance.
*Computer Cable Assemblies
Computer cable assemblies are those used within computers and between computers and their accessories. There are numerous types of computer cable accessories, such as Serial ATA (SATA) cables, VGA cables, and USB cables. SATA cable assemblies are used for connecting storage devices and computer motherboards. Typically, they have 8-pin connectors and provide high data transfer speeds. VGA cables connect computers to monitors, and feature 15-pin connectors in three rows which correspond to RGB channels. USB cables are perhaps the most well-known computer cable assembly and are used to connect many different types of accessories to computers. USB Type-A cable assemblies have connectors with four connection points that are used for power and data transfer.
*Flat Ribbon Cable Assemblies
As the name suggests, flat ribbon cable, or ribbon cable, assemblies have the appearance of a flat ribbon. They consist of a row of parallel wires that are neatly placed next to each other in a ribbon-like shape. The shape of these cable assemblies makes them ideal for confined spaces, especially where width is a key design factor. Flat ribbon cable assemblies come in split, multi-branch, non-PVC, and other types. These assemblies allow mass termination using insulation-displacement connectors (IDC) with sharp, forked contacts. IDC with ribbon cables is a wiring solution featuring a flat multiconductor cable paired with an Insulation-Displacement Connector (IDC). This connector is designed to pierce through insulation, establishing electrical connections with the conductors through sharp blades. They are cost-effective, easy to use, and high-density, and are easy to identify and maintain. While round cables are now preferred for external and internal connections, ribbon cables remain advantageous, particularly in space-constrained scenarios.
*Telecommunication Cable Assemblies
Different cable assemblies apply to the telecommunication sector. Two common examples of cable assemblies used in the telecommunication industry include fiber-optic cables and D-sub cable assemblies. D-subminiature connectors, originally designed as compact alternatives for use with electronic devices, are widely used in computer and telecommunications applications. Available in various configurations like: 9-pin, 15-pin, 25-pin, and 37-pin, with higher-density options for complex systems, D-sub cables commonly use thumbscrew locking mechanisms for secure connections, even under harsh conditions. Made of metal, the thumbscrew usually features a knurled surface for easy gripping and manual turning. The threaded shaft of the thumbscrew is inserted through a hole in one component and subsequently screwed into a threaded hole on the other, effectively securing the two components together. D-sub cables are cost-effective for high-density connectors. This is because of their ease of manufacturing and widespread availability in various pin counts and configurations. Their shielded wire also ensures reliable signal transmission.
*Networking and General Communication Cable Assemblies
Networking and general communication cable assemblies are cable assemblies used for creating a network of systems or computers, and generally facilitating communication. The most prevalent networking cable assemblies are Ethernet cables, with the Category 5e (Cat5e) cable being the most common. Cat5e cables contain four pairs of copper wires. The eight wires are individually wrapped in a protective sheath, with a single thermoplastic sheath covering the group of wires.
*Multicore Assembly
Multicore cable assemblies contain more than one usable signal or feed in a single core assembly. These assemblies are useful whenever a combination of feeds is needed in a single assembly. CCTV cable assemblies are an example of multicore assemblies, which combine signal and power in coaxial cables, to provide power and connectivity to CCTV cameras. Another example is the audio multicore cable which transmits multiple analog audio signals in a single cable assembly.
*Audio/visual (AV) Cable Assemblies
AV cable assemblies are designed and used to transmit audio and video signals. These assemblies typically include multiple conductors or wires, each dedicated to carrying specific signals, and they are often enclosed within a protective sheath. Examples of audio/visual cable assemblies include High-Definition Multimedia Interface (HDMI) cables, Video Graphics Array (VGA) cables, RCA cables, and other similar configurations. These cables are typically used in home entertainment systems (e.g., TVs), multimedia applications, and professional audio/video setups.
*RFI/EMI Shielded Cable Assemblies
Electromagnetic interference (EMI) and Radio frequency interference (RFI) shielded cable assemblies are cable assemblies that contain specialized shielding to protect against EMI or RFI. The shielding in these assemblies consists of a thin layer of aluminum, called foil, or a mesh of copper wires, called braiding, that cover the internal group of wires in a layer underneath the protective plastic sheath. Shielded cable assemblies protect against EMI and RFI, which cause noise and signal corruption. They are used in applications in which signal purity is needed, such as in security systems, audio cabling, and visual cables.
*Military Grade Cable Assemblies
Military-grade cable assemblies are designed to meet the rigorous demands of military and aerospace applications. These assemblies are used in different military systems, including aerospace equipment, field communication links, and marine equipment. An example of a cable assembly found in the military setting is the circular connector cable assembly. These military cable assemblies offer robust durability and secure connections resistant to contaminants, EMI, impact damage, moisture, and vibration. These assemblies accommodate multiple pins for power and data transmission. They are available in various gauges, materials, and designs, and they simplify maintenance with easy connection and disconnection. Circular cable assemblies are constructed from resilient materials like stainless steel, aluminum, and plastic. They resist corrosion, while waterproof versions enhance protection through advanced sealing technologies. They maintain a watertight seal even under high-pressure water exposure, thanks to advanced sealing technologies such as gaskets and O-rings. Waterproof circular connector cables are specifically engineered to ensure reliable and secure connections in challenging environments, safeguarding electrical systems from water, dust, and contaminants.

Wire Harness

1.Features of Wire Harness
Components of wire harnesses consist of wires, terminals and connectors organized into consolidated, concise bundling systems. Designs vary enormously depending on the system requirements of these devices. Some applications are not more than a superficial bundle of loose wires grouped into an available protective jacket. Other applications may require a more complex assembly of dozens of individually over-molded wires and cables that feature breakouts that radiate off in multiple directions to termination points or other junctions. Ultimately, wire harnesses supply efficient wiring solutions for electrical pieces of equipment and devices that will particularly impact those products’ overall performance, reliability, and stability.

2.Uses of Wire Harness
The wire harness is the combination of electrical cables, or assembly of wires, that connects all electrical and electronic (E/E) components in the automotive vehicle, like sensors, electronic control units, batteries, and actuators. The wiring harness handles the energy and information flow within the E/E system to fulfill primary car functions, such as steering and braking as well as secondary car functions, such as ventilation and infotainment. In addition, wire harnesses are utilized in nearly every conceivable household, industrial, or commercial device – tools, hardware, equipment, household, and machinery products – that relays or transmits electronic information or electrical power. The standard harness is definitely an essential, if not an indispensable, component in such devices. Wire harnesses are manufactured in various arrangements and sizes related to a device’s environmental and application requirements. The users can employ these devices anywhere from harsh outdoor climates with wide temperature extremes to temperature-controlled buildings, dwellings, or even marine environments at ocean level.

3.Common Types of Wire Harness
*Wire Harness Types Based on the Connectors Used
The sole purpose of a connector type wire harness is to transmit electrical signals from the wire harness to the power source. Connectors comprise of different plugs and jacks, the design being based on the function and performance required. There are essentially two main types of wire harness connectors – male and female, which serve to provide the necessary junctions between the many different elements of the wire harness, to produce efficient transmission of data, power, or signal through the system. In simple terms, plugs are male connectors, and jacks are female connectors. The performance of a connector is also related to the material used, the ease of connection, and the insulation between the pins. Different applications call for different connector types, as the functions, designs, and working vary from one condition to another. It is thus best to let your wire harness manufacturer in India know about your particular requirements, based on which you can have your harnesses designed.
*Wire Harness Types Based on the Terminals
Terminals are used in wire harnesses to cease the conductor to a particular point, and secure and protect the connection. Generally made of metal or alloy, these devices may also be composed of silicon or carbon, depending upon the application requirement. Available in a variety of different shapes, sizes, and designs, terminals can be used as hooks, rings, bullets, spades, or any other customizable design.
Hooks – These terminals, with an open end, are simple and efficient, with a high durability rating.
Rings – These terminals have a rounded end that lets it attach to screws and studs, which may be insulated and crimped or soldered onto the wires.
Bullets – These terminals are great for connections between male and female wire harness connectors.
Spades – These terminals, with a unique fork shape, have an easily-attachable open end, ideal for tight spaces.
Terminals are absolutely important for the design of the wire harness as they provide the necessary junction from which a cabling harness can be terminated or progressed to other components. Their design is highly crucial for producing a product with continuity, integrity, and safety.

Benefits of Custom Cable Assembly & Wire Harness

Better Control of Processes
When you choose custom cable assemblies and wire harnesses, you take control into your own hands and control how things work. Your only responsibility is to choose the right custom cable manufacturer and be transparent with all your requirements to avoid problems later.

Customization Makes Mass Production Easier
Most companies have no limit on the number of products they can produce. You can order the products you need and if you choose a reliable supplier who can meet the given timeline, the products will be delivered within the deadline. Not all cable assembly and wire harness manufacturers are reliable, so be careful and choose to work with a trustworthy company.

Help You Reduce Costs
This may sound confusing to some, as most custom products cost more than typical products on the market. But when you look at the bigger picture, you’ll realize that customer cable assemblies and wire harnesses can help you save money in the long run. When you get what you want, time and resources are reduced because nothing is wasted. Plus, you don’t have to request changes, saving time. You’ll be able to use that time elsewhere, which will ultimately help your bottom line.

Higher Quality
When it comes to cable assembly, quality is always a top priority. If you study the market, you will see different options. Some are of good quality, some not so good. You can choose a traditional assembly design or choose custom options that make everything more manageable.

Reduces Risk of Problems
People choose customization because it gives them more control over what they want. You must consider custom-made cable assemblies and wire harnesses because doing so reduces the risk of problems that may arise later. Possible problems include poor quality grouping, tangled wires, incorrect color selection, etc. These may sound like minor issues, but because legal requirements are often involved, they can result in huge losses. Depending on the location of your project or the type of cable you are assembling, your project may need to follow specific prerequisites. If not, then your project may end up in trouble. Therefore, opt for custom assembly to ensure your project is problem-free.

Management is Easier
With custom cable assemblies and wire harnesses, management will be a breeze as you won’t have to worry about untangling wires from time to time. Things will be tagged and categorized, and less time and effort will be required to perform maintenance or changes.

Improve Performance
Experience tells us that custom cable assemblies and wire harnesses can have a positive impact on overall performance. As mentioned before, this will help save time and your team will have more free time to focus on other responsibilities, which may lead to greater efficiency.

They Can Solve the Problem Very Well
Customization means you get what you want, order it and pay for it. Therefore, there is no risk of quality issues and your QA team does not have to waste time during or after installation ensuring quality standards are met.

Tips for Choosing the Right Custom Cable Assembly & Wire Harness Manufacturer

There are quite a few things to examine as you’re looking for the right manufacturer. We’ve assembled a list of the top things you should be looking for as you consider the best cable assembly and wire harness manufacturer for your projects.

Manufacturing Experience

When searching for a reliable china cable assembly manufacturer, it’s crucial to consider several factors to ensure you’re partnering with the right company. Look for a cable assembly china provider with a proven track record of delivering high-quality products and meeting deadlines consistently. Evaluate their technical expertise and manufacturing capabilities to ensure they can handle your specific requirements. A reputable china custom wire harness manufacturer should offer design assistance, prototyping services, and rigorous quality control measures. Additionally, consider their certifications, such as ISO 9001,ETL to guarantee adherence to international standards. Communication is key, so choose a manufacturer that is responsive and transparent throughout the production process. By carefully assessing these aspects, you can select a trustworthy partner for your chinese wire harness custom and wire harness needs in China.

Expertise and Experience in Your Industry

Every industry has its own exacting demands. That might be military or aerospace, or even medical applications. The right manufacturer for your requirements should have extensive experience meeting your industry’s and your applications’ demands. They can’t just acquire it when you show up with a prototype. They need to have “been there and done that,” so you’re not providing them with on-the-job training with your time and money.

Types of Cables that Match Your Needs

Providing custom cables for a specific industry is one thing. Even so, the right manufacturer also needs extensive experience with the type of cable assemblies and wire harnesses you need. So here again, it’s no good helping bring them up to speed on something new with your project and resources.

Extensive Design, Production, and Testing Resources

The best manufacturers provide quick prototype design, development, and rapid scaling into full-blown production. However, they must also have a never-ending drive for fast delivery backed up by extensive testing resources to ensure the highest quality.

Component Sourcing Capabilities

Any custom cable assemblies and wire harness manufacturer will have extensive component sourcing capabilities. Plus, they should be able to share their insight into where you’re most likely to run into problems. That will also help you to respond early and often to head off those problems before they happen. In addition, the right manufacturing partner can provide real-time supply issue updates, from shortages to discontinued connectors.

Speed of Delivery

Location and sourcing, coupled with extensive design, production, and testing resources, should optimize the speed of delivery for your custom cables. The manufacturer’s ability to collaborate with your team throughout the design and production process is a big part of that. Look for responsiveness during the selection process to choose the best manufacturer.

Lower Product Costs

This is always going to be on your list for any manufacturer. But ensure cost savings don’t cost you more in the long run. Those costs could be delayed manufacturing, cost overruns, and even failed projects. See the rest of the list and ensure everything is taken care of before you start tallying the product costs.

Certifications and Regulations

Manufacturing custom cable assemblies and wire harnesses isn’t something you can set up in your garage. Instead, it takes considerable expertise backed by industry certification, recognition, and regulation compliance. You can readily tell the top manufacturers from the list of certifications.

Personalized Customer Service

When it comes down to brass tacks, many companies have all the above items, but they lack personalized customer service. The right custom cable manufacturers engage you from your first moment of contact and through every step of every project. You can almost tell on the first call whether they have your interests at heart. This aspect should be weighted highly on your assessment of the right cable harness manufacturer for your business.

Our Factory

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Frequently Asked Questions

Q: What is the difference between a cable assembly and a wire harness?

A: The difference between cable assemblies and wire harnesses is that cable assemblies create a path from one point or circuit to another, while wire harnesses connect several points or circuits with multiple breakouts running in different directions, serving multiple functions with multiple terminations on each breakout.

Q: How long should a wiring harness last?

A: In automotive applications, a wiring harness can last for 15-20 years or even longer, as long as it is not exposed to excessive heat, moisture, or physical damage. In other applications, such as consumer electronics or industrial machinery, the lifespan may vary based on specific conditions and usage patterns.

Q: Why do wiring harnesses fail?

A: Some of the most common manufacturing mistakes occur due to improper wire layout, poor connection to the harness chassis, or the complexity of the design. Defective crimping or soldering also represents a common and critical issue in the manufacturing of wiring harnesses.

Q: How many hours does it take to install a wiring harness?

A: Installing a wiring harness could take as little as an hour, as long as 20 hours, or longer if complications arise. Despite the ambiguous answer for timing, dropping in a wiring harness is a significantly faster and safer way to install electrical assemblies compared to placing each wire one by one.

Q: What is the basic component of the cable assembly?

A: The basic component for a cable consists of the conductor metal wire/cable which the maximum current rating for the power/communication signal, protected by an insulating layer (plastic) and an optional shielding (depending on the cable, it is not a must).

Q: Is a wiring harness necessary?

A: A wiring harness is crucial for the protection of your electronics. Some of the main functions they serve include: Helping to increase the lifespan of your electronic device by protecting it from compromised wires and heat damage.

Q: Can a wiring harness be repaired?

A: If the damaged area is over 6 inches (15 cm), the harness can be repaired by adding overlay wiring over the damaged area.

Q: Why are wire harnesses twisted?

A: With concentric twisting, there are different layers and direction of the twist of the wires alternates with each layer. That keeps the loom nice and flexible, keeps everything neat and tidy and makes sure that none of the wires in the harness have more stress than others.

Q: Can cable assemblies be used as electrical wire?

A: Yes, cable assemblies can be used as electrical wires, but it’s important to understand the difference between these two. An electrical wire typically refers to a single conductor or a group of conductors (wires) without any additional components. It is the basic building block of an electrical circuit. Wires are often used for transmitting electrical power or signals. On the other hand, a cable assembly is a more complex structure that consists of one or more electrical cables with connectors, terminations, protective jackets, and possibly other components. Cable assemblies are pre-assembled and ready-to-use solutions designed for specific applications. They can include multiple wires or conductors bundled together and enclosed in an outer protective sheath. So, a cable assembly can function as an electrical wire, but it typically provides additional features such as: connectors, insulation, and protection. However, although cable assemblies can be used to transmit electricity through the wires in their assembly, each assembly is best used only for its intended purpose.

Q: What industries use cable assemblies?

A: Cable assemblies serve a wide range of industries that require electronic hardware, including, but not limited to: technology and electronics, automotive, medical, aerospace and aviation, industrial machinery, consumer electronics, telecommunications, networking, energy and power distribution, and military and defense.

Q: How to choose a cable assembly?

A: Choosing the right cable assembly comes down to the end-use application. There are several key factors to consider to ensure a cable assembly aligns with the specific needs of your application. Start by identifying the purpose, whether it’s for power transmission, data transfer, or audio/video signals. Determine the types of signals the cable will handle and choose a cable assembly designed to meet those frequency and bandwidth requirements. Finally, select connectors compatible with your devices and ensure they match the equipment’s requirements.

Q: What is the difference between a cable assembly and a cable?

A: A cable is a set of at least two wires or conductors wrapped in a single insulating jacket. A cable assembly is a group of cables enclosed in a single protective sheath.

Q: What is the function of cable assembly?

A: Cable assemblies serve three primary purposes: To protect outside factors from harm caused by the flow of electricity. To ensure wiring systems are organized and straightforward for technicians to understand. To protect the wiring or cable against wear and tear or other harsh environmental conditions.

Q: What are the common faults of wiring harness?

A: These defects can include poor-quality materials, incorrect assembly, or inadequate insulation. Manufacturing defects often lead to short circuits, open circuits, or intermittent connections, which can result in a malfunctioning device or even a fire.

Q: What causes a wiring harness to go bad?

A: Wiring harnesses are machine-made. If the machine isn’t well maintained or the technician applies incorrect settings, wiring harness problems can result. Some of the most common manufacturing mistakes occur due to improper wire layout, poor connection to the harness chassis, or the complexity of the design.

Q: When should I replace my wiring harness?

A: Discolored wires or melted insulation should be replaced before any other repairs are performed on the harness. Less than 20% of the harness is damaged. If the wire damage is greater than 6 inches (15 cm), an overlay harness can be added to replace the section of damaged wire. More than 20% of the harness is damaged.

We’re professional custom cable assembly & wire harness manufacturers and suppliers in China, specialized in providing high quality products and service. We warmly welcome you to wholesale custom cable assembly & wire harness from our factory. Contact us for pricelist and quotation.

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