Custom Wire Harnesses

Customized wire and cable assemblies streamline installation, save space in enclosures, and ensure devices have exactly the insulation, connectors, and other components they need. Learn about Captor Corporation’s custom wire harness manufacturing capabilities.

What Are Wire Harnesses?

The term “cable assembly” is often used interchangeably with “wire harness. ” While there is considerable overlap between these two assemblies, there are differences based on the complexity of the application. Cable assemblies are groups of wires or cables enclosed with insulation and a protective exterior sheath or jacket, and bound at the ends with connectors.
In contrast, wire harnesses are made up of groups of cable assemblies or wires and multiple connectors. They tend to be designed and configured for specific applications, and usually consist of these components:

A single conductor or bundle of conductors.
Interior sheaths that insulate or protect the conductors (and end users).
Exterior covering.
Connectors.

Benefits of Custom Wire Harnesses

Cost-effective, standard wire harnesses are available to meet the needs of some common applications; however, they can also be customized with different types of insulation, connectors, or groupings of wires based on the requirements of the application. Consider these benefits of working with custom wire harness manufacturers to provide wire assemblies.

Time Savings
Time Savings
Wire harnesses significantly reduce the amount of time assemblers or end-users need to spend installing wires and setting up equipment. An all-in-one wire harness makes it much simpler to connect the right wires or cables at the right points. This results in greater clarity, fewer mistakes, and less rework and is especially valuable for complex electronic systems.
Space-Efficiency
Space-Efficiency
Individual wires and cables, especially if they are much longer than the application requires, take up space when coiled to fit a small area. Custom wire harnesses can save space inside enclosures and at workstations because all of the wire types are combined into as few distinct cables as possible, and they can be trimmed to the required length, making them dense and compact to better fit within the device or component. In very compact assemblies, the space saved can even be used for improved ventilation and thermal management.
Safety and Protection
Safety and Protection
Standard wiring assemblies can create trip hazards or become loose or unplugged over time. This is a significant safety hazard in consumer applications as well as in busy commercial or industrial spaces.
Custom wire harnesses improve safety because they include optimal insulating jackets and sheaths for the application. Depending on the design, the exterior covers can protect against:
- Some moisture exposure.
- Impact stress.
- Temperature changes.
- Electrical shock as people move or handle the cables.
Customizability
Customizability
Custom wire harnesses can meet the exact design requirements of electronic and electrical assemblies, incorporating precisely the right connectors, wire gauges, and material lengths for any product.

Captor's Custom Wire Harness Capabilities

Captor Corporation produces high-quality custom wire harnesses. Our company fabricates cable assemblies, wire harnesses, and wiring products for multiple different industries, including aerospace, automotive, electromechanical, and military fields. We stock various sizes and types of wire, crimp and solder terminals, and connectors and can create an assembly that meets your requirements. Our capabilities include:

Manufacturing assemblies with solid, stranded, or other wiring types in 30 to 4/0 AWG.
Inserting commercial, crimped, D-Sub, IEC, military, or other connector types.
Providing crimp and solder terminal options.
Testing products to guarantee product performance and alignment with project parameters.

As part of our commitment to creating high-performance custom wire harnesses, we have an on-staff IPC/WHMA-A-620 Certified Trainer who certifies team members on best practices and compliant assembly processes.

Order Your Custom Wire Harnesses From Captor Corporation

Custom wire harnesses simplify installation, fit better in constrained spaces, and meet your specific performance requirements. Captor Corporation is a leading manufacturer of custom wire and cable assemblies for major industries, and we work hard to provide high-quality products in a timely manner.

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