How to design a proper cable assembly: Buzz from Industry Expert

 What is Cable Assembly?


Cable Assembly is perhaps the main components of an electronic or electrical framework. It is fundamentally a gathering of wires or links that are coordinated and incorporated into a single unit and it is made of heavy-duty materials like thermoplastic rubber.

Cable harness assembly is specially intended to transmit electric force and signals. The cable assembly is otherwise called a wiring looms or a link tackle. You will actually want to discover different cables relying upon various shapes, sizes, shadings, lengths, and applications too


cable assembly


Process of Cable Assembly:

The wire harness assembly process is a bit tricky, time-consuming, and task-oriented that’s only because the wire harness is one of the most indispensable electronic components in the modern world. So, let’s understand the process of Cable assembly in brief:

Step 1: Designing

Designing is one of the most important parts of the custom designing for each product of electronic parts. At this stage, all the engineers and designers are addressed to choose harness components and decide and use other specifications. Engineers and Designers ordinarily face a ton of difficulties while designing the harness assembly and the principal challenge involves a handcraft for every item electronic part and gradually step by step the measure is utilized to finish the designing part of cable harness assembly

Important points to consider while designing a cable Assembly are as below:

– Overall Size

– Flexibility

– Electrical requirements

– Standards Agency postings UL accreditation, CSA affirmation, CE Mark

  Environment- Where the cable is being used

Step 2: Prototyping

The second most important step in the process of designing cable assembly is prototyping as it allows the designer or an engineer to see the final product; usually, it is used to check the performance of the product. They can test the wire harness in the application before starting the foremost production run and also ensures optimal performance.

Advantages of prototyping in the process of cable assembly:

         Availability of components

         Ease of cable assembly

         Environmental factors

         Can check quality standards for better results and also

         Reveals design flaws

Step 3: Production and Assembly

In Cable Harness Manufacturing the most important is design specifications and that should meet the high-quality standards and that too with minimal errors and that is the reason engineers prefer prototyping. But remarkably in this modern age where manufacturing is expanding globally, wire harness manufacturing still depends on manual assembly. Though some automation can include the process but hand manufacturing in cable assemblies is necessary. 

Advantages of Production and assembly:

         Reduce Overall costs

         Perfect Fit

         Faster turnaround time

         Controls the overall process

         Better materials

         QA/QC (Quality assurance and Quality control)

Steps included in hand manufacturing of cable assembly:

         Wire cutting


         Connecting and then ends at assembly

Step 4: Testing

The last step in the process of the cable assembly is testing. Once production is completed each harness should undergo testing for any specifications. It is very important because all the engineers and designers should know the final product performance and that should be 100 % safe and secure.

Importance of Cable testing

         Testing for damage

         Saving costs

         Finding flaws

And Industries that serve cable assemblies areas follows:

         Cable Assemblies for Medical Industry

         Cable Assemblies for Telecom

         Cable Assemblies for Military Applications

         Cable Assemblies for industrial controls


Hence, the above mentioned is the process of cable assembly which is usually taken into consideration. If you are confused about the process or application you can consult an Industry Expert. I will surely come up with more such interesting articles. Feel Free to contact Jayshree Instruments for detailed information.

Author Bio

Rutul Bhatt is a leading entrepreneur in electronics manufacturing, and also director of a company named Jayshree Instruments which was previously named as Digital Corporation in 1992. Because of his deeper knowledge in the Electronics Manufacturing Industry, he’s been able to deal with Toshiba TV kit manufacturing for 4 years. A solution for innovative products is making him special in this field.

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