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Cable Assembly

Image of Cable Assembly

The wires are first cut to the desired length, usually using a special wire-cutting machine.  After this, the ends of the wires are stripped to expose the cores, which are fitted with any required terminal or connector housings. The cables are assembled according to the design specification, to form the cable harness.  After fitting any protective sleeves or conduit the harness is either fitted directly in the end product or shipped to the client.


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CDG can manufacture cable harnesses using the following techniques

  • crimping terminals onto wires, multiple crimps (more than one wire into one terminal)
  • Tinning of wire ends and soldered connections
  • routing wires through sleeves
  • inserting one sleeve into another
  • fastening strands with tape, clamps or cable ties

It is difficult to automate these processes. Manual production remains more cost effective than automation, especially with small batch sizes.

Testing the electrical functionality of a cable harness can be done with the aid of a test board. The circuit diagram data are pre-programmed into the test board, where harnesses can be tested individually or in multiple numbers.