INTEGRATED WIRING • IPC/WHMA-A-620 • TURNKEY PCBA
Wire Harness Assembly Services
Harness assemblies act as the nervous system of your electronics. We manage requirements capture through testing so every harness arrives labeled, traceable, and ready to install alongside your PCBAs and box builds.
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Wire harness assembly: The nervous system of your electronics
Harness assemblies power modern electronics
APTPCB's custom wire harness assembly: Your integrated wiring expert
Custom wire harness expertise
Core advantages: Why choose APTPCB for your wire harness needs
Organization efficiency & reliability
Optimized organization & enhanced assembly efficiency
Reduced clutter
Our wire harnesses consolidate numerous individual wires into a single, neat unit, significantly streamlining internal wiring.
Simplified installation
Pre-fabricated and tested harnesses drastically reduce manual assembly time, cutting labor costs and minimizing installation errors during PCBA final assembly.
Improved airflow & serviceability
Organized wiring optimizes airflow for better heat dissipation in dense PCBA designs and simplifies future maintenance or upgrades.
Significantly enhanced product reliability & durability
Superior protection
Harnesses provide robust defense against environmental factors like moisture, dust, chemicals, and abrasion.
Reduced risk of failure
Minimizes the occurrence of short circuits, electrical failures, and connection issues, ensuring long-term system stability, complementing your PCBA's inherent reliability.
Vibration & strain resistance
Expertly designed harnesses offer superior stability in high-vibration environments, preventing connection fatigue and stress on the PCB assembly.
Cost-effectiveness & space optimization
Achieving superior cost-effectiveness
Lower manufacturing costs
Automated and standardized harness production reduces manual labor, rejects, and rework compared to individual wire routing.
Reduced maintenance & warranty costs
High reliability translates to fewer field failures, less troubleshooting, and lower warranty claims, protecting your PCBA investment.
Extended product lifespan
A durable wire harness extends the operational life of the entire electronic system, boosting product value.
Ultimate space optimization & weight reduction
Compact designs
Precisely engineered harnesses maximize the utilization of limited space, facilitating product miniaturization crucial for modern PCB designs.
Weight optimization
Strategic material selection and optimized routing paths contribute to lower overall system weight, critical for aerospace and portable devices.
Flexible & safe routing
Provides highly flexible and secure routing solutions for complex, densely packed electrical layouts and multi-layer PCB assemblies.
Quality consistency & customization
Ensuring consistency & controllable quality
Standardized production
Adherence to strict manufacturing standards and processes guarantees consistent quality across all production batches.
Efficient quality control
Centralized testing and inspection protocols for harnesses are more thorough and efficient, catching potential issues early.
Stable performance
Ensures uniform electrical performance, signal integrity, and mechanical robustness, vital for mission-critical PCBA projects.
Offering highly customized engineering options
Tailored specifications
Custom wire lengths, gauges, colors, and insulation materials to perfectly match your electrical requirements.
Specialized connectors & terminals
Integration of standard or custom connectors, terminals, and precise crimping solutions.
Advanced protection & shielding
Options for various jacket materials, braided shielding for EMI/RFI suppression, overmolding, and specialized strain relief, directly impacting your PCB's signal integrity.
Wire harness design and pre-production process at APTPCB
Five-step design & pre-production workflow
- 1
Comprehensive requirements gathering & definition
Thoroughly define the specific use case, operating conditions (temperature, vibration, moisture, chemicals), expected lifespan, power/signal types (analog, digital, RF), voltage, current, impedance, bandwidth, and all relevant industry standards (UL, IPC/WHMA-A-620, ISO, IATF 16949) and customer requirements.
- 2
Schematic design & bill of materials (BOM) generation
Create detailed electrical schematics and wiring diagrams that accurately map all connections, splices, and component placements; precisely define wire types (stranded, solid, coaxial), gauges (AWG), colors, insulation materials, connector families, terminal types; generate a complete Bill of Materials for all harness components.
- 3
Advanced 3D modeling & routing simulation
Utilize state-of-the-art 3D CAD software to create a virtual model of the wire harness within the final product assembly; simulate wire routing paths to ensure efficiency, prevent interference, optimize bend radii, and maximize space utilization; identify potential clashes or clearance issues with other components, including the PCBA itself, enclosures, and mechanical parts.
- 4
Material selection & prototyping for validation
Select appropriate conductor materials (copper alloys), insulation (PVC, XLPE, PTFE, Silicone), jacket materials, shielding (braids, foils), and connector plating (gold, tin, silver) based on performance requirements, cost, and environmental factors; fabricate functional prototypes to verify design accuracy, confirm fit, form, and function, and conduct initial performance, durability, and environmental tests.
- 5
Meticulous documentation & revision control
Generate clear, step-by-step manufacturing instructions, including visual aids and torque specifications; document all required quality control and testing protocols (continuity, insulation resistance, pull force, functional); maintain a meticulous revision history and change management log for complete traceability, essential for both wire harness and PCBA production.
APTPCB's advanced wire harness manufacturing process
Seven-step advanced manufacturing process
- 1
Precision wire preparation
Wires are cut to exact specified lengths and precisely stripped of insulation using high-speed automated machines (e.g., Schleuniger, Komax); terminals are crimped onto wire ends using semi-automatic or fully automatic crimping machines with calibrated tools, ensuring optimal pull-out force and electrical integrity; for specific high-reliability connections, wires are precisely tinned or soldered by IPC-certified operators.
- 2
Subassembly & kitting
All necessary wires, connectors, terminals, and protective coverings are kitted per the BOM and design specifications, ready for assembly; wires are grouped into smaller sub-bundles to manage complexity and simplify the main assembly process; any splices, intermediate connectors, or passive/active components are added to sub-assemblies.
- 3
Layout & bundling on formboards
Specialized assembly boards (formboards) are prepared, mirroring the exact layout and dimensions of the final harness; wires are meticulously routed and positioned on the formboard according to the wiring diagram; wires are secured using various methods such as cable ties, lacing cord, spiral wrap, or adhesive tape, forming the harness into its final specified shape and dimensions.
- 4
Connector & contact assembly
Prepared wires with crimped or soldered terminals are carefully inserted into connector housings, ensuring correct pin assignment; contacts are securely seated within the connectors using specialized insertion tools; environmental seals, strain relief backshells, and protective caps are added as required for mechanical and environmental protection.
- 5
Application of protective coverings
Various protective coverings are applied, including plastic tubing (PVC, polyethylene, nylon), braided sleeving (PET, fiberglass, metallic for EMI), heat-shrink tubing for tight fits, and specialized tapes; for enhanced durability, environmental sealing, and strain relief, specific sections of the harness (e.g., connector interfaces) can be overmolded with thermoplastic materials.
- 6
Labeling & identification systems
Clear, durable wire markers or labels (e.g., heat-shrinkable, adhesive) are applied for easy identification during installation and troubleshooting; harness-level identification tags or barcodes are added for full traceability from raw materials to finished product; standardized color-coding schemes are strictly followed to enhance recognition and reduce assembly errors.
- 7
Rigorous quality control & integrated testing
Each wire harness undergoes thorough visual inspection for defects, errors, proper assembly, and compliance with IPC/WHMA-A-620 standards; automated test fixtures verify every connection, identifying open circuits, short circuits, miswires, and correct pin assignments; insulation resistance testing checks for adequate insulation between conductors; high-voltage (dielectric withstanding voltage - DWV) testing ensures insulation can withstand specified voltage levels; destructive and non-destructive pull force tests verify mechanical strength; environmental & functional testing subjects harnesses to simulated real-world conditions; X-ray inspection is used for specific complex or high-reliability connections.
Integrated quality & testing
Electrical validation
Continuity & pin-out
Automated fixtures verify opens, shorts, miswires, and impedance targets.
Insulation & DWV
Hi-pot and insulation resistance testing prevent leakage and breakdown.
Signal integrity
Optional TDR and EMI characterization for high-speed or RF harnesses.
Mechanical & environmental
Pull & flex
Destructive and non-destructive pull tests plus flex cycling validate robustness.
Environmental stress
Temperature, humidity, vibration, and chemical exposure simulate field use.
Functional verification
Harnesses connect to actual PCBAs or fixtures to confirm end-system performance.
Choose APTPCB for your custom wire harness assembly needs
Why choose APTPCB for wire harness assemblies
- •Expert design & engineering support: Tailored solutions from concept to reality, informed by our extensive PCBA design expertise.
- •Advanced manufacturing capabilities: State-of-the-art equipment and processes, mirroring the high standards of our PCB fabrication.
- •Rigorous quality control: Comprehensive testing and inspection procedures, integrated with our PCBA testing protocols, ensuring flawless performance.
- •Cross-industry expertise: Proven experience across the most demanding sectors, including automotive, aerospace, medical, industrial, and consumer electronics.
- •Competitive pricing: Cost-effective solutions without compromising on the critical quality or reliability of your wiring.
- •Responsive customer support: A dedicated team committed to assisting you throughout the project lifecycle, from initial PCB prototyping to final product delivery.
Partner with APTPCB for superior electrical connectivity
Need harnesses aligned with your next build?
Share harness drawings, PCB interface requirements, compliance targets, and schedules—we’ll return optimized designs, quotes, and readiness checkpoints within one business day.
Frequently Asked Questions
What wire gauges and types do you support?
Fine-pitch signal wires through heavy-duty power cables, including stranded, solid, coaxial, shielded, and hybrid constructions.
Can harnesses be co-developed with PCBAs?
Yes—our engineers run 3D routing validations, mechanical fit checks, and functional tests with your PCBAs before release.
How do you ensure environmental protection?
We specify moisture, dust, chemical, and abrasion-resistant jackets, plus overmolding and strain relief for harsh use.
What certifications and documentation come with shipments?
IPC/WHMA-A-620 workmanship, UL/CE/RoHS support, traveler traceability, inspection photos, and test reports are provided as needed.
Can you scale from prototype to production?
Absolutely—we handle prototypes, pilot runs, and volume programs with the same tooling, inspection, and support teams.