Amplifying Product Performance with Right Cable and Wire Harness

Cable and wire harnesses are important components of electronic systems. When assembling a system, cable harness manufacturers heavily consider the design before getting started. Different components go into the cable and wire harness assembly phases. When it comes to the process, it is essential for harness manufacturing companies to neither over design nor under design.


At the beginning stages of cable and wire harness assembly, the environment utilized needs to be considered. In extreme weather conditions, products can be exposed to flexing, and wire harnesses and cables should be able to tolerate the flex. In a cleanroom area, the assembly should be able to tolerate sunlight and moisture.


When it comes to the assembly process, the best materials need to be used to meet assembly expectations. Conductors are commonly used in the assembly process but the number of them needed varies. Different options are available for conductive material with a common one being copper. Copper is used with a variety of different coatings, such as nickel and silver. These materials allow for cable assembly to be done in high-temperature environmental settings.

Depending on where the custom cable assembly is used will determine the material, thickness, and type of primary insulation. Materials are determined as assembly details are made known, such as the environment exposed, voltage levels, chemicals, etc. In extreme conditions, more durable compounds are utilized to ensure proper functioning.


Cable types are dependent on the applications for which they will be used. An example is a coaxial cable. This cable is commonly used for noise-sensitive applications, RF applications, and other simple applications. The sizing of the conductor wires needs to be properly sized so that voltages operate properly.

Conductor Cabling

When in close contact, cables can make unwanted noise. To avoid this issue, conductors should be twisted to reduce noise as signals are being transmitted.

Outer Sheath

An outer sheath is a protective covering that is applied after a cable core is finished. This layer needs to be able to withstand harsh environments while being flexible in movement. The outer sheath needs to be chemically resistant and semi-conductive.

Conductor Reliefs

Ensuring that the speed of a signal from a cable assembly is being transmitted fast enough is essential.


To allow for sensitive areas of cables from being damaged, cables need to be routed near to the chassis. This is where vibrations and movement are felt.

Star Engineering

When searching on Google for “wire harness manufacturing near me,” to provide a wire harness assembly solution, contact Star Engineering. Star Engineering produces custom electrical and electronic solutions for customers. For 40 years, Star Engineering has provided high quality and speed of delivery. For more information, Contact Star Engineering today.

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