Choosing the suitable wire harness or cable assembly for your project is essential for the original equipment manufacturing (OEM) process. The choice you make can be the difference between a successful or failing device or industrial process. And choosing between off-the-shelf and custom-made products is one of the most important choices you have to make.
While off-the-shelf solutions may work when dealing with simple applications, they often fall short in the case of more complex or critical applications – to the point where they can be disastrous. That’s why wire harness and cable assembly customization is necessary to ensure that your equipment will function properly and deliver the expected results.
Custom wire harnesses and cable assemblies are designed and manufactured specifically to your requirements. As such, they are a valuable solution for OEMs.
Continue reading to find out more about why wire harness and cable assembly customization is necessary.
The difference between standard and custom wire harness and cable assembly
First, let’s look into the difference between standard (off-the-shelf) and custom wire harnesses and cable assemblies.
On the one hand, standard wire harnesses and cable assemblies are widely available and easily purchased in electrical shops. These off-the-shelf products might be a good option for simple things, such as organizing the tv and internet routing cables in your home. However, you do not choose to find the right length with the suitable conductor, output, and the right connector. That’s to say that finding the right solution for your application can be very difficult, if not impossible.
That’s where custom wire harnesses and cable assemblies come in. As the name suggests, these custom products are designed and manufactured to fulfill your specific application requirements.
In terms of price, the standard, mass-market wire harnesses, and cable assemblies are cheaper than custom-made ones. They are typically made out of cheap material and for simple tasks. So, while you may save in terms of price, you will also receive a poorer performance. Not to mention that it may be next to impossible to find the right one.
When you are working with a good custom wire harness and cable assembly manufacturer, you have the option to choose the material, type of conductor, insulation, length, and all the other specifications you need. As such, while more expensive, these custom products will perform better than standard ones, will be stronger, and live longer.
The benefits of wire harness and cable assembly customization
Here are some of the benefits of wire harness and cable assembly customization:
Vast customization possibilities
The main benefit of a custom wire harness and cable assembly is the vast customization possibilities. These products are essential components in various industries and their electrical systems, each with its specific set of requirements. Custom wire harnesses and cable assemblies consider all your particular needs, from the environment the product will be used at, the required power, cable length, and the needed components. You can even choose to customize the colour of the cables and wires to facilitate the process of installation and maintenance.
Working with an expert wire harness and cable assembly manufacturer, you will be able to create the “perfect fit” for your application. This is the main selling point of wire harness and cable assembly customization.
Opportunity to prototype and test
The prototype and testing phase are core steps in finding that “perfect fit” mentioned above. Before committing to purchase the total amount of wire harnesses or cable assemblies you need for your project, you will, of course, need first to test them and ensure they meet your exact requirements.
The wire harness and cable assembly customization process allow you to test the product and make changes if necessary. This is done in the prototyping stage. A prototype is the tangible “draft” of a custom design that the user can test in real-life situations.
During the testing phase, you will see what works and what needs altering. This way, the opportunity to the prototype will save you a lot of time and money in the long run as it allows you to avoid costly mistakes.
Higher product quality
When working with a custom wire harness and cable assembly manufacturer, you get full control over choosing high-quality source materials that are suitable for the intended product application. Remember, standard wire harnesses and cable assemblies you will find at your local electrical store are typically made out of cheap materials that will not last long, especially if you intend to use them under harsh environmental conditions such as extreme temperatures or saltwater.
That’s why custom wire harnesses and cable assemblies are designed specifically for your environmental requirements. The prototype is tested in its element during the testing phase to see how its components will react to it in real life.
Moreover, wire harness and cable assembly manufacturers will ensure the products go through meticulous quality assurance and quality control (QA/QC) processes.
Higher performance
Given the higher product quality and the fact that custom wire harnesses and cable assemblies are designed and manufactured to fit your exact requirements – plus the rigorous testing they undergo, these custom solutions will perform up to the intended expectations. Off-the-shelf products cannot match their performance.
Save time and money in the long run
While a standard wire harness of cable assembly might seem cheaper to purchase at first, in the end, they may end up costing you more money. In most cases, an off-the-shelf product will not be a “perfect fit” for its intended application. So you might end up going back and forth with making changes and struggling to find the right one, wasting money and time. At the same time, their cheaper quality may lead to premature equipment failure and a need for replacement.
On the other hand, while a custom wire harness or cable assembly may be pricier upfront, its higher quality will save you money in the long run as you won’t need to change them as often.
Moreover, since these custom products undergo rigorous testing, they will be a “perfect fit” for their intended application. In addition, a custom wire harness or cable assembly will come with easy-to-install connectors and proper labeling. This will save you a lot of precious time during the equipment manufacturing process.
In conclusion: why are wire harness and cable assembly customization necessary?
Off-the-shelf wire harness and cable assemblies may work for simple applications. However, more often than not, they won’t be able to fit your needs perfectly. Then it’s time you turn to custom-made ones.
Custom wire harnesses and cable assemblies are designed, tested, and manufactured according to your requirements. As such, they offer significant benefits for OEMs, including:
- Vast customization possibilities
- Opportunity to prototype and test
- Higher product quality
- Higher performance
- Save time and money in the long run
These advantages make wire harness and cable assembly customization a necessary solution for OEMs across various industries.
