Wire Harness Assembly

Consolidated Electronic Wire & Cable has provided custom wire harness assembly services to diverse industrial markets since 1919. As a dedicated wire harness assembly manufacturer, we can design and engineer custom wire harness assemblies for complex systems or manufacture them to your custom specifications. Learn more about our manufacturing steps, industries we serve, and quality certifications.

Why Choose Consolidated Electronic Wire & Cable?

We maintain a large inventory of ready-to-ship products to support rapid deployment. If standard configurations fall short of your engineering requirements, our technical team can produce custom solutions for your project. As a single-source supplier, we simplify complex supply chain logistics and help lower your total procurement costs.

Our Wire Harness Assembly Process

As a trusted wire harness assembly company, we follow a standardized, meticulous process that undergoes strict quality checks.

Wire Preparation

Technicians cut raw wire to exact lengths and strip the insulation without damaging the underlying copper conductors.

Crimping

Mechanical presses attach metal contacts to the exposed wire ends to create secure electrical connections.

Soldering

Melted metal alloy is applied to specific joints to reinforce mechanical strength and electrical conductivity.

Terminal Assembly

We insert the crimped or soldered wires into plastic connector housings based on strict pinout diagrams.

Harness Routing

The bundled wires are laid out on a physical pin board to establish the correct shape and precise branch lengths.

Testing

Machines run continuity and high-voltage tests to identify short circuits or incorrect pin alignments.

Engineer’s Note: Specify high-flex stranded wire instead of solid-core conductors for high-vibration environments like automotive engine bays or industrial robotics. This material choice helps prevent premature metal fatigue and electrical failure.

Protective Covering

We apply durable braided sleeves, corrugated tubing, or heat-shrink tape to protect the internal wires against abrasion and moisture.

Labeling and Marking

Operators attach heat-shrink labels or barcode tags to specific branches to streamline final field installation.

Quality Inspection

Dedicated inspectors verify the finished product against the original engineering drawings to confirm that dimensional tolerances are met.

Industries We Serve

We produce robust wire harness assemblies to support specialized markets across the globe, including but not limited to:

Data centers. We supply reliable medium-voltage cables and wire harness assemblies for large-scale server infrastructure.
OEMs. Original equipment manufacturers use our wire harness assemblies in industrial equipment for safe and reliable operation.
Industrial. We produce rugged wire harnesses that withstand aggressive chemical exposure and heavy physical impact on the factory floor.
Medical. Our facility produces precise wiring systems for sensitive diagnostic equipment and patient monitoring devices.
Automotive. Our components power complex vehicle lighting, sensor networks, and dashboard controls.

Our Certifications

Strict regulatory compliance protects your final manufactured product. Consolidated Electronic Wire & Cable produces components in compliance with ISO 9001:2015 certification, RoHS, Mil-Spec, and other standards. We maintain rigorous documentation to support your internal quality audits and protect your supply chain.

Contact Consolidated Electronic Wire & Cable for Custom Wire Harness Assemblies

Partnering with a reliable wire harness assembly manufacturer streamlines your procurement schedule. Consolidated Electronic Wire & Cable supports critical industries with reliable wire harness assembly services, collaborating with your engineering team to design a custom assembly or producing them to your existing specifications. We provide multiple options for shielding, fillers, materials, style, and more to meet your requirements.

Custom Wire Harness Assembly