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Connectors assembled to wire harness

Common Connector Types for Custom Wire Harnesses

Key Takeaways (Executive Summary) The "Big Three": Molex, TE Connectivity (formerly Tyco/AMP), and JST are the industry standards. Most other brands are compatible "clones" of these designs. Pitch is Everything:...

Common Connector Types for Custom Wire Harnesses

Key Takeaways (Executive Summary) The "Big Three": Molex, TE Connectivity (formerly Tyco/AMP), and JST are the industry standards. Most other brands are compatible "clones" of these designs. Pitch is Everything:...

A Guide to AWG (American Wire Gauge) for Custom Cable & Wire Harness Assemblies

A Guide to AWG (American Wire Gauge) for Custom...

Key Takeaways (Executive Summary) The Inverse Rule: AWG works backwards. A smaller number means a thicker wire (e.g., 10 AWG is thick, 30 AWG is thin). Ampacity: The gauge determines...

A Guide to AWG (American Wire Gauge) for Custom...

Key Takeaways (Executive Summary) The Inverse Rule: AWG works backwards. A smaller number means a thicker wire (e.g., 10 AWG is thick, 30 AWG is thin). Ampacity: The gauge determines...

From Spool to Assembly: The Custom Cable Assembly & Wire Harness Manufacturing Process

From Spool to Assembly: The Custom Cable Assemb...

Key Takeaways (Executive Summary) The Mix: Modern cable manufacturing is a hybrid of high-speed automation (for precision cutting and crimping) and skilled manual labor (for complex routing and final assembly)....

From Spool to Assembly: The Custom Cable Assemb...

Key Takeaways (Executive Summary) The Mix: Modern cable manufacturing is a hybrid of high-speed automation (for precision cutting and crimping) and skilled manual labor (for complex routing and final assembly)....

Cable Shielding 101: Foil, Braid, and Spiral Wraps

Cable Shielding 101: Foil, Braid, and Spiral Wraps

Key Takeaways (Executive Summary) The Enemy: Shielding protects signals from EMI (Electromagnetic Interference) and RFI (Radio Frequency Interference), which can cause data errors or audio hum. Foil Shielding: Thin aluminum/Mylar...

Cable Shielding 101: Foil, Braid, and Spiral Wraps

Key Takeaways (Executive Summary) The Enemy: Shielding protects signals from EMI (Electromagnetic Interference) and RFI (Radio Frequency Interference), which can cause data errors or audio hum. Foil Shielding: Thin aluminum/Mylar...

Choosing the Right Wire Insulation: PVC vs. PTFE vs. Silicone

Choosing the Right Wire Insulation: PVC vs. PTF...

Key Takeaways (Executive Summary) PVC (Polyvinyl Chloride): The industry standard. Low cost, easy to process, but melts easily and becomes brittle in freezing temperatures. Ideal for consumer electronics. PTFE (Teflon):...

Choosing the Right Wire Insulation: PVC vs. PTF...

Key Takeaways (Executive Summary) PVC (Polyvinyl Chloride): The industry standard. Low cost, easy to process, but melts easily and becomes brittle in freezing temperatures. Ideal for consumer electronics. PTFE (Teflon):...

Crimping vs. Soldering: Which Connection is More Reliable for Wire Harness?

Crimping vs. Soldering: Which Connection is Mor...

Key Takeaways (Executive Summary) The Verdict: For wire harnesses subjected to vibration (vehicles, machinery), crimping is superior to soldering because it avoids "wicking," which makes wires brittle. The Mechanism: A...

Crimping vs. Soldering: Which Connection is Mor...

Key Takeaways (Executive Summary) The Verdict: For wire harnesses subjected to vibration (vehicles, machinery), crimping is superior to soldering because it avoids "wicking," which makes wires brittle. The Mechanism: A...

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