Benefits of Cable Assemblies & Wire Harnesses

What are custom cable assemblies? 

Cable assemblies and wire harnesses are specialised services that tailor cable and wire configurations to meet the specific electrical requirements of various applications and industries. This customisation includes choosing the type, length, wire gauge, connectors, and sheathing to ensure that each cable assembly perfectly fits its intended use. 

This process typically starts with a detailed assessment of the application's needs, followed by the cable and wire harness design, prototyping, and manufacturing. 

Key Benefits of Custom Cable Assemblies     

1. Enhanced Performance & Flexibility 

By tailoring cable assemblies and wire harnesses to the exact specifications needed, manufacturers can enhance the overall performance of the equipment. Custom cables can be optimised for signal integrity, power handling, and durability, ensuring a precise fit for the intended application, minimising the risk of errors or malfunctions. 

2. Environmental Compatibility  

Custom cables and wire harnesses can be designed with specific materials that are suited to their operating environment. For instance, assemblies can be made with UV-resistant sheathing for outdoor use or reinforced with abrasion-resistant materials for industrial settings. This customization helps in extending the lifespan of the cable assembly under its specific operating conditions. 

3. Space Efficiency 

In many applications, space is at a premium. Custom cable assemblies and wire harnesses can be designed to fit into tight spaces, reducing unnecessary bulk and improving the overall design of the system. This is particularly important in complex devices or compact consumer electronics. 

4. Reduced Installation Time 

Custom cables are pre-assembled to fit specific configurations, the method significantly reduces the time and effort required for installation. This can lead to faster assembly lines and quicker turnaround times in manufacturing processes, seamlessly integrating into existing systems, and providing a hassle-free setup experience. 

5. Cost-Effectiveness 

Although the initial cost of designing and producing custom cable assemblies might be higher than purchasing standard cables, the long-term savings are significant. Custom cable assemblies are less likely to need replacement due to failure or inefficiency, and the reduction in installation time can also lower overall labor costs. Tailoring cables to exact specifications minimizes material waste, contributing to sustainability efforts. 

6. Compliance and Safety 

Custom cable assemblies can be designed to meet strict industry standards and certifications, ensuring compliance with safety, quality, and environmental regulations. This is essential in industries like medical, automotive, and industrial, where safety and reliability are paramount. 

How complex is cable assembly manufacturing? 

It depends—sometimes cable assembly manufacturing can be quite complex. This process demands precision in cable and wire design and material selection, along with meticulous engineering to tailor specifications for specific applications.

The choice of cable assembly and wire harness materials, such as conductors and insulators, is crucial for quality assurance. Advanced manufacturing techniques, including cutting, stripping, crimping, and molding, also play a vital role in ensuring high-quality products. Each assembly undergoes thorough testing to meet safety and performance standards, with customisation options available for unique cable connector types and configurations. Adhering to strict regulatory standards like UL, IEEE, and RoHS adds another layer of complexity.  

Taking all these design elements into account, whether you have a detailed design in mind or need expert advice to determine the best solution for your requirements, our team is here to help produce a design that is both functional and economical for your application.

Ideal Applications Using Cable Assemblies and Wire Harnesses: 

• Automotive & Vehicle Manufacturing 
• Smart/IoT Devices 
• Medical & Healthcare 
• Artificial Intelligence 
• Industrial Machinery 
• Power Distribution 
• Telecom 
• Lighting 
• Sustainable Energy

Why choose Active Components?

Extensive Industry Experience: 

With over 41 years in the electronics component industry and project experience, we possess deep knowledge across a wide range of projects, enabling us to deliver high-quality, reliable custom cable assemblies. 

Collaboration with Global Manufacturers: 

We collaborate closely with leading global cable assembly and wire harness manufacturers to customise components like connectors and cable accessories to meet specific customer requirements. 

Inventory Management and Stock Availability: 

We provide inventory management services from our warehouses, with options to hold stock in New Zealand and Hong Kong. This ensures that our customers can quickly respond to spikes in demand or plan against demand forecasts.