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Custom Wire Harness Manufacturer

Consolidated Electronic Wire & Cable is proud to offer a wide selection of top-quality, custom wire harnesses.

Wire harnesses are designed to streamline and organize multi-wire systems in aerospace, automotive, commercial, medical, residential, and telecommunications applications, among others. At Consolidated Electronic Wire & Cable, we’re proud to offer a broad selection of superior-quality, customized wire harnesses. With more than 100 years of industry experience, our expert team can create a wire harness solution tailored to nearly any specification while ensuring the highest level of precision and care.

The Benefits of Wire Harnesses Solutions from Consolidated

When you partner with Consolidated for your custom wire harness needs, you’ll gain access to the following benefits:

Customizable wire harness solutions for nearly any application

Customizable wire harness solutions for nearly any application

Expert design and engineering services

Expert design and engineering services

Wide range of component and material options

Wide range of component and material options

Stringent quality control and testing procedures

Stringent quality control and testing procedures

Faster assembly speeds and reduced costs

Faster assembly speeds and reduced costs

The Components of Custom Wire Harness

The Components of Custom Wire Harness The Components of Custom Wire Harness

1Terminal Position Assurance

The Terminal Position Assurance (TPA) helps ensure secure retention when the receptacle and header are mated. This also helps prevent the contact from backing out.

2LED Lamp

LED Lamps can be used anywhere you need low power, high intensity reliable light or indication. These components are available in multiple colors and intensities.

3Panel Mount Push Button Switch

The Panel Mount Push Button Switch is simply used to turn something on or off. This also allows for the start or stop of action.

4Cable Strain Relief

The Cabin Strain Relief alleviates the cable of stresses and tensions that could break inner conductors. It also provides a liquid tight seal around the cable.

5Push Mount Cable Tie

The Push Mount Cable Tie can attach to the panel or cabinet and secures a bundle of cables or wires. This helps keep your system organized and free of obstructions.

6Axial Cooling Fan

The Axial Cooling Fan helps prevent the equipment from overheating. This also helps extend the overall lifespan of the equipment.

7Multi Conductor Cable

The Multi Conductor Cable is used to transmit multiple power or electronic signals from one point to another.

8Wire to Board or Wire to Wire Connector

The Wire to Board (or Wire to Wire) Connector is used to make power or electronic signal connection through the mating of connectors or headers. Available variations include locking features and multi-positions.

9Assembly Label

The Assembly Label is used to easily identify the part number, lot code, manufacturer, and date.

10Quick Disconnect Terminals

Quick Disconnect Terminals are a simple and secure method to give power to connections. These are offered in both uninsulated and insulated.

The Components of Custom Wire Harness

1 2 3 4 5 6 7 8 9 10
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Terminal Position Assurance

Terminal Position Assurance

The Terminal Position Assurance (TPA) helps ensure secure retention when the receptacle and header are mated. This also helps prevent the contact from backing out.

Close
LED Lamp

LED Lamp

LED Lamps can be used anywhere you need low power, high intensity reliable light or indication. These components are available in multiple colors and intensities.

Close
Panel Mount Push Button Switch

Panel Mount Push Button Switch

The Panel Mount Push Button Switch is simply used to turn something on or off. This also allows for the start or stop of action.

Close
Cable Strain Relief

Cable Strain Relief

The Cabin Strain Relief alleviates the cable of stresses and tensions that could break inner conductors. It also provides a liquid tight seal around the cable.

Close
Push Mount Cable Tie

Push Mount Cable Tie

The Push Mount Cable Tie can attach to the panel or cabinet and secures a bundle of cables or wires. This helps keep your system organized and free of obstructions.

Close
Axial Cooling Fan

Axial Cooling Fan

The Axial Cooling Fan helps prevent the equipment from overheating. This also helps extend the overall lifespan of the equipment.

Close
Multi Conductor Cable

Multi Conductor Cable

The Multi Conductor Cable is used to transmit multiple power or electronic signals from one point to another.

Close
Wire to Board or Wire to Wire Connector

Wire to Board or Wire to Wire Connector

The Wire to Board (or Wire to Wire) Connector is used to make power or electronic signal connection through the mating of connectors or headers. Available variations include locking features and multi-positions.

Close
Assembly Label

Assembly Label

The Assembly Label is used to easily identify the part number, lot code, manufacturer, and date.

Close
Quick Disconnect Terminals

Quick Disconnect Terminals

Quick Disconnect Terminals are a simple and secure method to give power to connections. These are offered in both uninsulated and insulated.

Our Wiring Harness Capabilities

We can manufacture custom wire harnesses with the following specifications:

Voltage Handling

Up to 600 volts (UL) or 3000 volts (military)

Temperature Range

-65°C (-85°F) to 250°C (482°F)

Insulator Materials

Depending on your needs, we offer various insulator materials:

  • Cellular (foam) polyethylene
  • Cross-linked polyethylene (XLPE)
  • ECTFE Halar
  • ETFE Tefzel
  • Ethylene propylene diene monomer (EPDM)
  • Fluorinated ethylene propylene (FEP)
  • Irradiated polyvinyl chloride (IRR/PVC)
  • Low-density polyethylene (LPDE) and high-density polyethylene (HDPE)
  • Low-smoke plenum copolymer
  • PVDF Kynar
  • Polyethylene (PE)
  • Polypropylene (PP) and cellular (foam) PP
  • Polytetrafluoroethylene (PTFE)
  • Polyurethane (PU) and polyurethane and nylon blends
  • Polyvinyl chloride (PVC)
  • Semi-rigid polyvinyl chloride (SR-PVC)
  • Tetrafluoroethylene (TFE)
  • Thermoplastic elastomers (TPE/TPR)
  • Vinyl

Protection

Custom shielding and heat-shrink coatings

Identification

Custom labeling/barcoding, four-color ink stamping, independent circuit IDs, and individual tagging

Fillers

Paper, nylon, and polypropylene

Compliance

IPC/WHMA-A-620, military, UL, and other applicable standards

Industries Served

Wire harnesses offer a solution for various interconnection challenges across numerous industries. Due to their ability to enhance efficiency and protect workers from hazardous wiring, nearly every industry can benefit from custom wire harnesses. At Consolidated Electronic Wire & Cable, we can provide tailored wire harnesses for the following sectors:

Why Work With Consolidated Electronic Wire & Cable

Consolidate has been delivering reliable solutions for over 100 years. We are a one-stop shop for custom and standard electronic wire, cables, wire harnesses, molded cable assemblies, and power supply cords.

100+ Years of Experience
100+ Years of Experience
Smarter Inventory Control with Warehousing
Smarter Inventory Control with Warehousing
Large Breadth of Capabilities - A one-stop shop
Large Breadth of Capabilities - A one-stop shop

Quality Assured: Our Certifications

As a testament to our quality and reputation, we hold a diverse range of certifications, including:

ISO 9001
RoHS
CE Mark
NEC
UL
CSA Group
OSHA
VDE
Lead Free
Military Standard Certified

Client Success Stories: Our Case Studies

Custom Wire Harness for the Pump Manufacturing Industry
Custom Wire Harness for the Pump Manufacturing Industry Consolidated was able to supply A customer specializing in audio sensor monitoring... Learn More
Custom Cable Harness Assembly for Industrial Controller Panel
Custom Cable Harness Assembly for Industrial Controller Panel To meet our customer’s needs Consolidated developed an effective, workable design.... Learn More
The Expert Guide to Wire Harnesses

The Expert Guide to Wire Harnesses

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Contact Consolidated, Your Trusted Wire Harness Manufacturer

Consolidated Electronic Wire & Cable has helped clients develop reliable wire harness solutions for over 100 years. Our state-of-the-art production facilities allow us to create custom wire harnesses tailored to your unique application, all while maintaining optimal quality and compliance with industry standards. With numerous options for fillers, shielding, style, materials, and identification, we are well-equipped to meet nearly any need.

For more information about our custom wire harness capabilities, or to get started on your next project, contact us or request a quote today.

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