Wire Harness

Quality Assurance and Compliance

Wire harness manufacturing requires consistent workmanship and verification against the applicable product specifications and customer acceptance criteria.

Stantek maintains an ISO 9001:2015 by Smithers Quality Assessments. View Certificate quality management system through Smithers Quality Assessments. Inspection and verification requirements are established according to the relevant drawings, specifications, and project documentation.

IPC/WHMA-A-620 may apply to cable and wire harness workmanship and acceptance requirements. J-STD-001 may be relevant where soldered electrical assemblies are involved. Applicability depends on the product and contract; neither standard should be interpreted as automatic certification of every wire harness.

Stantek also maintains DDTC registration and ITAR compliance for applicable defense-related work. Customers should identify any program-specific requirements for documentation, traceability, handling, and regulatory compliance when requesting a quotation.

Custom Wire Harness Manufacturing Capabilities

Stantek provides manufacturing capabilities for preparing, identifying, terminating, arranging, and assembling wires according to customer specifications. The processes selected for each project depend on the harness configuration, specified components, production quantity, and acceptance criteria.

Our capabilities include:

• Wire Cutting and Stripping: Preparing wires to specified lengths and termination requirements.
• Wire Identification and Marking: Using supported laser or hot-stamp marking processes to identify wires according to project requirements.
• Terminal Crimping and Connector Integration: Applying specified terminals and connectors to the required wire configurations.
• Ultrasonic Splicing: Joining compatible conductors where the materials and assembly requirements support the process.
• Wire Grouping and Routing: Arranging conductors and branch points according to the documented harness layout.
• Protective Coverings: Applying specified sleeving, braiding, or other supported protective materials.
• Harness Assembly: Organizing and assembling wires and components according to the applicable drawings, bills of materials, and production instructions.

Not every process applies to every wire harness. Stantek establishes the manufacturing approach according to the documented requirements and the capabilities available for the project.

Wire Harness Testing and Quality Verification

Testing and inspection help verify that a wire harness meets the electrical and workmanship requirements defined for the project. The appropriate verification methods depend on the harness configuration, customer specifications, and agreed acceptance criteria.

Depending on the project and available test equipment, verification may include:

• Continuity Testing: Checking specified circuits to confirm that electrical paths are continuous.
• Open-Circuit and Short-Circuit Checks: Identifying unintended interruptions or electrical connections between circuits.
• Workmanship Inspection: Checking wire preparation, terminations, connectors, routing, identification, and other specified assembly details.
• Additional Specified Electrical Tests: Performing other tests when required by the project specifications and supported by the available equipment.

Stantek’s custom Cirris testing capability supports applicable electrical verification requirements. Customers should identify required test limits, acceptance criteria, and documentation during the quotation and project review process.

Benefits of Working with Stantek

Choosing a wire harness manufacturer involves more than selecting a supplier to assemble wires and connectors. Customers also need clear communication about specifications, component requirements, production quantities, quality expectations, and delivery planning.

Stantek supports suitable customer programs through:

• Build-to-Print Manufacturing: Wire harnesses produced to customer-provided drawings, bills of materials, and specifications.
• Initial Design Consultation: Discussions and manufacturability feedback to clarify production requirements before manufacturing.
• Low-to-Mid-Volume Production: Manufacturing support for suitable prototype builds, initial orders, and recurring production quantities.
• Configuration-Specific Assembly: Wire grouping, branch points, identification, terminations, and protective coverings based on the required harness layout.
• Production Coordination: Communication about components, order quantities, lead times, and project requirements.
• U.S.-Based Manufacturing: Production at Stantek’s facility in Stanton, Kentucky.

These capabilities help customers establish a defined manufacturing approach for wire harnesses used in their equipment and systems.

Our Wire Harness Manufacturing Process

Stantek follows the project documentation and agreed production requirements to manufacture each wire harness. The exact sequence depends on the harness layout, component specifications, and required inspection criteria.

1. Requirement Review: Review available drawings, wiring diagrams, bills of materials, quantities, and application requirements.
2. Component Verification: Check specified wires, terminals, connectors, identification requirements, and protective materials against the project documentation.
3. Wire Preparation: Cut, strip, mark, and prepare wires according to the documented requirements.
4. Termination and Harness Assembly: Apply specified terminals and connectors, arrange wire groups, form required branches, and assemble the harness configuration.
5. Inspection and Verification: Check the completed assembly against applicable drawings, workmanship requirements, and agreed testing criteria.
6. Documentation and Order Preparation: Complete required records and prepare conforming assemblies for shipment according to the agreed order requirements.

The production sequence and verification activities depend on the requirements agreed for each project.

Industries and Applications for Custom Wire Harnesses

Custom wire harnesses organize electrical connections into defined configurations for equipment and systems requiring multiple wires, connectors, and circuits. Stantek manufactures custom wire harnesses to customer specifications for applicable OEM and industrial applications across the following industries.

• Aerospace  

  Aerospace applications may require wire harnesses for aircraft systems, avionics support equipment, and ground support equipment. These assemblies can incorporate specified wires, connectors, branch points, and protective coverings. Manufacturing follows customer drawings, component specifications, and applicable program requirements.

• Defense 

  Defense applications use wire harnesses to connect electrical components across specified equipment and systems. Harness configurations may require defined routing, connector arrangements, shielding, and documentation according to the application. Stantek manufactures assemblies to customer specifications and addresses applicable traceability and regulatory requirements.

• Technology 

  Technology equipment may use custom wire harnesses to connect electronic components, control units, communication equipment, and computing hardware. Organized wiring supports defined connection layouts within compact equipment and enclosures. Each assembly is configured according to customer specifications, connector requirements, and the intended application.

• Medical
  

  Medical equipment may incorporate wire harnesses to connect electrical components in diagnostic devices, laboratory equipment, and other specified systems. Harness assemblies can organize multiple circuits and connectors to support equipment integration. Material selection, documentation, and testing requirements depend on the customer’s specifications and the intended application.

• Automotive 

  Automotive and related transportation applications use wire harnesses to connect vehicle electronics, sensors, controls, and other electrical components. Assemblies may include multiple branches, connector configurations, and protective coverings to suit the equipment layout. Manufacturing follows the customer’s drawings, specifications, and applicable acceptance criteria.

• Marine 

  Marine applications may require wire harnesses for onboard electrical systems, navigation equipment, communication systems, and vessel controls. Depending on the operating environment, specifications may define requirements for insulation, routing, connector selection, and protective coverings. Each harness is manufactured according to the application’s electrical and environmental requirements.

• Robotics & Automation 

  Robotics and automation systems use wire harnesses to connect sensors, actuators, controllers, and other electrical components. Harness layouts may need to accommodate defined routing paths, multiple connection points, and repeated equipment movement. Stantek manufactures assemblies to customer specifications for applicable robotic systems, industrial machinery, and automated production equipment.

The required wire types, conductor sizes, circuit layout, connectors, branch points, protective coverings, and verification methods vary by application. Stantek reviews the applicable specifications and manufacturing requirements during project evaluation and quotation.

From Prototype to Production

Stantek supports suitable prototype, quick-turn, and low-to-mid-volume wire harness programs. An initial build can help clarify assembly requirements and establish the documented configuration before recurring production.

Moving from an initial build to repeat orders depends on specification readiness, component availability, required inspection and testing, production quantities, and the agreed project schedule.

For an initial review, provide the available drawings, wiring diagrams, bills of materials, estimated quantity, and target delivery date. If production details need clarification, Stantek can discuss the requirements and provide initial design consultation or manufacturability feedback.

What to Include in Your Wire Harness Specifications

Clear specifications help a wire harness manufacturer understand the required configuration and prepare an accurate quotation. Include as many of the following details as are available.

• Drawings and Wiring Diagrams: Current drawings, circuit diagrams, revision levels, and bills of materials.
• Wire Requirements: Wire type, conductor size, length, insulation, color, and other specified characteristics.
• Circuit and Routing Details: Wire groupings, branch points, routing layout, and connection arrangements.
• Terminals and Connectors: Required part numbers, termination methods, and connector configurations.
• Identification Requirements: Wire labels, markings, color coding, and identification conventions.
• Operating Conditions: Applicable temperature, vibration, moisture, abrasion, or other environmental requirements.
• Testing and Quality Criteria: Required electrical tests, inspection criteria, acceptance limits, records, and traceability requirements.
• Quantity and Schedule: Prototype quantity, initial order volume, anticipated recurring demand, and requested delivery date.

Not every project requires every item. If some information is unavailable, share the documentation you have so the outstanding requirements can be identified during the initial review.

Request a Quote for Custom Wire Harnesses

Need custom wire harnesses built to your specifications? Contact Stantek to discuss your requirements and request a quote.

Share your available drawings, bill of materials, wire types, connector configurations, required quantities, and target schedule. Our team will review the information provided and identify any additional details needed to evaluate your project. Whether you require prototype wire harnesses or low-to-mid-volume production, Stantek can assess your requirements based on your specifications. Get in touch to discuss your custom wire harness needs.