Wires and Cables
Conductors typically copper or aluminum—that transmit electrical power or signals.
PCB Unlimited provides wire harness manufacturing services tailored to a broad range of industries, including aerospace, automotive, industrial equipment, medical devices, and telecommunications.
A wire harness is an organized assembly of wires and cables, bundled together with connectors, terminals, and protective components, designed to transmit electrical power or signals within a device, machine, or system.
Wire harness manufacturing is the end-to-end process of designing, assembling, and testing wire harnesses. It typically involves cutting, stripping, terminating, and assembling wires using a combination of automated machinery and manual labor, due to the complexity and variation of tasks involved.
Conductors typically copper or aluminum—that transmit electrical power or signals.
Interface devices that securely join wires to other wires or components.
Points in the harness where wires connect to other components using metal end crimping or soldering.
A layer of material to protect the wires and prevent shorts, moisture, and environmental damage
Additional coverings such as plastic tubing, fabric wrap, or heat shrink to shield wires from abrasion, heat, and moisture
Clips, ties, or fasteners used to secure the wire harness in place.
The first step in the wire harness process is to create a 2D/3D assembly diagram/schematic defining routing, lengths, gauges, connectors, and protective measures. This is done typically using CAD software that generates the BOM (Bill of Materials) and formboard layout.
Several factors need to be considered when designing wire harnesses including type and size of wires, connectors type, how components are connected, esthetics and ergonomics.
Wires are cut to length using automated machines like MultiStrip 9480. Insulation is removed at connection points.
Wires are labeled with inkjet printers or heat shrink markers.
Terminals are applied using pneumatic or electric crimping machines like CT 60. Crimp quality is monitored in real-time using CFM systems.
Technicians route wires on a layout board using clamps, guides, and connectors.
Tying, bundling, and taping to guarantee correct grouping and orientation.
Wires are inserted into connectors and protective sleeves.
Heat-shrink tubing can be used for sealing and strain relief.
Electrical testing includes continuity, shorts, insulation resistance, and pinout verification. Automated testers can be used to compare results with predefined configurations.
Final harnesses are coiled, labeled, and packed to prevent damage during transport. Documentation and traceability tags are included.
DESIGN & ENGINEERING
MANUFACTURING
TESTING AND QUALITY ASSURANCE
Wire Cutting & Stripping Machines
Crimping Machines
Harness Test Benches
Heat Shrink Ovens
Labeling Machines
Formboards & Assembly Fixtures
The Schleuniger EcoCut 3300 can automatically cut all kinds of material including wire, cable, round material such as tubing, flat ribbon and Glass Fiber Optic (GOF) cable.
It processes wire up to 16 mm² (6 AWG), cuts round material up to 12 mm (0.47") O.D. and cuts flat material up to 100 mm (3.94") wide.
Flat Cables
Round cables, profile
Shrink Tubing
Thin metallic, nonmetallic sheets
Tubing
Wire marking
Woven fabric
The Schleuniger Strip Series B300 stripping machine performs reliable stripping of cables with cross sections from 0.03 to 8 mm2 (32 to 8 AWG).
Discrete Wire Processing
Full Strip
Multiconductor Cable Stripping
Partial Strip
The Schleuniger MultiStrip 9480 is a high-performance, fully automatic wire cutting and stripping machine designed for precision and versatility for a variety of wire harness applications.
Cut to length
Full or partial strip left and right
Jacket and inner conductor stripping
Jacket stripping of extremely thin insulations
Jacket stripping of multiconductor cables
Multilayer stripping
Multilayer with shield processing (coax, hybrid, etc.)
Multistep jacket stripping with inner conductor stripping and window slitting
Multistep stripping
Trimming, separating and stripping of individual zipcord conductors
Wire marking
The Schleuniger CT 60 is a pneumatic benchtop crimping machine engineered for high-force, loose-piece crimping applications. It delivers up to 60 kN (6.7 tons) of parallel crimping force, making it suitable for processing a wide range of terminal types and wire sizes.
The quality of the crimp is guaranteed by a full-cycle mechanism that assures that the dies have closed completely before they are reopened.
The Schleuniger UniCrimp 208 is a high-performance benchtop crimping machine designed for precise and efficient crimping of rear-feed and side-feed banded terminals. With a crimping force of 33 kN (3.3 tons), it accommodates a wide range of wire sizes and terminal types, making it ideal for various wire harness assembly applications.
Discrete wire crimping
Multiconductor cable crimping
The Schleuniger StripCrimp 208 stripping machine combines the standard working processes of cable processing in a single machine. Short breakout lengths of 22 mm (0.86") and even down to 10 mm (0.39") using special tools permit the processing of sensor applications.
Discrete wire crimping
Discrete wire stripping
Discrete wire stripping & crimping
Multiconductor cable crimping
Multiconductor cable stripping
Multiconductor cable stripping & crimping
Multistep stripping
The semiautomatic Schleuniger CoaxStrip 6480 stripping machine processes coaxial cables with an outer diameter of 1.2 to 12 millimeters.
It is equipped with "cable end detection" and "cable diameter verification."
The WTT Wire Terminal Pull Tester is designed to test the pull-out force of crimped wire terminals. It features a digital display for accurate force measurement and can be used for quality control in wire harness production.
The tester helps ensure that crimped connections meet required specifications and industry standards for pull-out strength.
Combines multiple wires into one assembly, reducing clutter and improving organization.
Reduces material waste and installation time.
Designed to fit specific system requirements.
Withstands mechanical stress and environmental exposure.
Used for engines, lighting, infotainment systems, and more.
Supports critical avionics and communication systems.
Found in imaging equipment, diagnostic tools, and patient monitors.
Powers automated systems and robotics.
Provides connectivity in appliances, computers, and audio systems.
If you're looking for more technical details or advice on wire harness design, manufacturing, or suppliers, feel free to ask!