How to design custom cables?

October/11/2023

When designing a custom wiring harness (custom cables or harness assemblies), it is essential to consider electrical, mechanical, environmental, and assembly factors. Below is a comprehensive design process and key points for reference:

1. Define Requirements

Application Scenario:
- Is it used in automotive, industrial equipment, medical devices, consumer electronics, or other fields?
- Working environment: high temperature, humidity, waterproof, dustproof, oil resistance, vibration resistance?
Electrical Parameters:
- Voltage and current requirements
- Signal types (power wires, signal wires, data wires such as USB/HDMI/CAN, etc.)
Connector Type:
- What connectors are used (USB, JST, Molex, Deutsch, AMP, industrial aviation plugs, etc.)
- Number of pins, pitch, locking mechanism
Installation Environment:
- Installation shape, dimensions, angle, bend radius; typical orientations include 45°, 90° (L-type), 135°, and U-type exits.
Appearance:
- Wire color, connector molding color
- Glossy or matte wire and connector surface
- Connector logo or indicator design

2. Component Selection and Design

Wire Selection:
- Conductor material (copper, tinned copper)
- Wire gauge (AWG), chosen based on current
- Insulation material (PVC, XLPE, silicone, TPE, etc.)
- Sheath type (single core, multi-core, shielded, braided, dual sheath)
Structural Design:
- Is shielding needed for EMI protection?
- Use of corrugated tubes, braided sleeving, heat shrink tubing for external protection
- Cable length and branching (e.g., Y-type splitters, T-type joints)
Connection Method:
- Soldering, crimping, IDC (insulation displacement), screw terminals, etc.
- Overmolding to reinforce connection points

3. Drawings and BOM

Wiring Diagram (can use AutoCAD, Electrical CAD, SolidWorks Electrical):
- Indicate color, length, terminal model, connector model, pin numbers, front and side views of connectors
- Clear branch structure, routing direction, and angles
- Wiring definition, also called wiring diagram
- Model dimensions, shapes, and special designs
- Process requirements, testing requirements, units of measurement, etc.
Generate BOM (Bill of Materials):
- Assign codes to each wire, terminal, connector, tubing, label, etc.
- Include quantity, specification, supplier, notes, etc.

4. Sample Production and Testing

Prototyping:
- Build 1–3 prototype sets for installation and testing
Testing Items:
- Continuity test (open/short circuit)
- Pull test (connection reliability)
- Insulation test (high-voltage withstand)
- Environmental testing (if needed: salt spray, temperature/humidity test)
- Functional test with equipment (power and signal testing)

5. Mass Production and Quality Control

Process Documents:
- Work instructions for each step (wire cutting, crimping, assembly, overmolding, inspection)
Labeling and Traceability:
- Label information: part number, batch number, date
- Barcode or QR code traceability system (if needed)
Quality Inspection Process:

Incoming inspection (wires, terminals)
In-process and final product inspection

short tips.

1.Choose connectors,connector 1,and connector 2,or connector 3 and ect.
2.Choose tooling,based on your application field,such as machine and so on.
3.Choose Wire,such as wire structure,UL no. ,color,and so on.
4.Design Wire diagram.
5.Remark tolerance,BOM
6.Other requirement.

If you share your application scenario or requirements, I can help you draft a tailored custom wiring harness design proposal or provide specific selection suggestions. Want to try designing one together?

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