Technical guides, buying advice, and manufacturing insights from our engineering team.
Learn when overmolding improves cable assembly performance and when it only adds cost. Covers material selection, tooling strategy, insert geometry, IP sealing limits, common failure modes, validation tests, and an RFQ checklist for buyers and engineers.
Learn how to specify drag chain and continuous-flex cable assemblies for robotics, CNC machines, and factory automation. Covers conductor class, jacket materials, shielding, bend radius, torsion, test methods, common failure modes, and a practical RFQ checklist.
Complete guide to cable assemblies — definition, key components (conductors, insulation, connectors, shielding, jacket), 8 major types, the manufacturing process from wire cutting to final test, industry applications across automotive, medical, industrial, and telecom, plus a 7-point specification checklist and IPC/WHMA-A-620 standards reference.
Decode portable cord letter codes (S, J, O, W, T, E) and compare the 10 most common NEC Article 400 cord types — SOOW, SJOOW, SEOOW, STW, SJTW — by voltage, jacket material, ampacity, and application. Includes AWG-to-ampacity tables, rubber vs PVC vs TPE trade-offs, and a specification guide for industrial, outdoor, and cold-climate use.
Detailed breakdown of wire harness cost layers — materials, labor, tooling, testing, and overhead. Includes pricing tables by complexity and volume, cost-by-application benchmarks, how to read a supplier quote, and 7 proven strategies to reduce cost without sacrificing quality.
Compare conductor, insulation, connector, terminal, and sheathing materials for wire harnesses. Covers PVC vs XLPE vs silicone vs PTFE, copper vs aluminum conductors, connector housing options, and material selection by industry with specs, costs, and trade-offs.
Complete guide to wire harness testing — continuity, insulation resistance, hipot, pull force, cross-section analysis, environmental, and functional testing. Includes test protocol matrices by industry and IPC/WHMA-A-620 requirements.
Step-by-step wire crimping guide covering tool selection, terminal types, the 6-step crimping process, 7 common mistakes that cause field failures, and quality inspection methods per IPC/WHMA-A-620 standards.
Compare copper braid, aluminum foil, spiral wrap, and combination shielding for cable assemblies. Covers frequency performance, flex life, termination methods, cost, and a decision guide for selecting the right shield.
Everything you need to know about IPC/WHMA-A-620 — the only industry-consensus standard for cable and wire harness assemblies. Covers product classes, key workmanship requirements, Rev F changes, certification, and how to apply the standard in procurement.
Learn 10 actionable Design for Manufacturability (DFM) tips for wire harness projects. Reduce cost by 30–50%, shorten lead times, and avoid common mistakes that cause rework and delays.