Ever wondered how a wiring harness is made? Better yet, want to know what a wiring harness is all about? Well, you’ll find all this and other wire harness assembly details you should know of below.

If you are keen enough, you’ll notice that wiring harness is practically everywhere. In fact, a number of electric-powered or electronic devices make use of or depend on the wiring harness. But what is it? Well, it is basically a group of wires put together. These wires usually start and terminate with a different type of connectors. The connector wiring that’s given usually depends on the function that it’s meant for.

While still on matters definition, it is good to point out that wiring harness, depending on where you are or look, tends to have different names. In some places, it is referred to as cable assembly, cable harness or wiring assembly.

How Is Wiring Harness Made?

With some little knowledge of what wiring harness is, it is time to focus on how it’s made. So how is it made? Well, before answering this important question it’s important to note that there is a wide variety of tech-based products that use wiring harness.

Despite this fact, however, the process of wire harness assembling is usually the same. And yes, regardless of the tech-based product or the industry it is of use.

The process of wiring harness usually starts with the cutting of wires. This helps in achieving or meeting certain specifics. Why is this? Well, different industries and different tech products require specified wiring harness. In other words, the wiring harness that best works for them.

For this to happen, make sure you cut wires to meet certain length specifications. A specialised wire-cutting machine is perfect for this. Once the wires are cut, the ends are carefully stripped to expose the wire’s cores.

The next step is fitting wires with connector or terminal housings. With this step, it is important that you get the right connector or terminal housing. When settling on an ideal connector or terminal housing, there are two things you want to focus on. These two are the size and its specifications. Factor these two while settling on a terminal or connector and you’ll definitely make the right choice.

Once you’ve done all the above, the next and last step in wiring harness is to harness the wires. This usually involves an assembly board or a workbench. Always make sure your workbench or assembly meets the design specification.  This helps you correctly carry out a wiring harness process.

Wiring Harness Using Hands or Machines

A question many ask when it comes to wiring harness is, does it require you to use your hands or a machine. If you are among those asking this question the answer is both. You can opt to use your hands and you can as well use a machine. Key to note however is that both processes require one to use a wide variety of processes.

These processes include the taping of wires, inserting and routing wires or cables appropriately through sleeves using tapes to fasten strands and crimping terminals. With fastening strands, you can opt for either cable ties or clamps in addition to using tapes.

Important to note when it comes to the subject of using hands or machines in wiring harness is that the whole process involves too many steps. Why is this important? Well, depending on the steps you’ll need, you can opt for semi-automatic machinery or hands. Not to worry however if you don’t understand all this as we are here to assist you.

Where Is Wiring Harness Needed?

While I’ve slightly touched on where you’ll need wiring harness above, this section highlights additional areas where it’s of good use. That said a wiring harness is most needed within a closed system with many types of equipment. The same is also true with different types of machineries.

For instance, it is of great use to cars as it helps in transmitting signals and electric power. The fact that it involves the process of collecting and putting wires together by way of bundles makes wiring harness ideal for these two. To ensure that the wires don’t stray away, they are bound carefully together using sleeves, cable lacing, tapes, and even cable straps and ties.

Why Is Wiring Harness Important?

There are two key reasons why wiring harness is important. These two are protecting wires and preventing short circuits. Let’s first look at how wiring harness helps protect wires.

With wire harnessing, it is important to assemble cables very closely. What this does is basically secure the wires in a protective suit. This way, you get to protect or shield the wires from natural effects like moisture or abrasion.

Furthermore, binding wires together using a suitable material helps in making an environment appealing. Do you prefer wires to be lying on the floor scattered everywhere? Or do you prefer when they are nicely bundled together? If you prefer the latter, wiring harness makes for a perfect solution.  

Reason number two is preventing short-circuits. With a mass of scattered wires lying around, chances of a short-circuit happening greatly increases. Why? Well, leaving wires scattered exposes them to a number of short-circuiting agents. Furthermore, it presents less work to the person doing the installation process of the wires. As opposed to working with several wires, wiring harness allows an installer to work with only one bundle.

Even better, one can opt to standardise the whole process given that the entire process involves only one bundle. With a barrage of wires or cables, the ability to standardise or even notation inculcating is very difficult. In addition to all these, it helps in reducing sparks which in some cases results in fires. For this to be a reality, however, one would need to bound the wires using a fire-retarding sleeve.


If you happen to be shopping for wire harnesses, look no further than Wiring Solutions. Our full-service team of experienced professionals will create your wire harness assembly from its prototype to the final product. To contact Wiring Solutions, dial (08) 8234 2670. You can also send an email to enquiries@wiringsolutions.com.au.