Meridian Cable designs and manufacturers custom wire harnesses for the exacting standards within medical, military, telecommunications, industrial controls, and more. We’re pleased to offer cutting-edge design capability working in tandem with a skilled manufacturing team in order to bring about the perfect amalgamation of cables, wires, and various components and accomplish the task at hand in the most economical means possible.
Our manufacturing capabilities in the U.S. and in China means we have developed our supply chain into an incredibly lean and efficient mechanism for delivering to clients around the world, even under tough conditions. See how working with a custom wire harness manufacturer can mean a better product and better return for your investment overall.
Customizable Features for any Wire Harness
Ranging from a simple pair of basic terminals to a complex web of multiple conductors, Meridian Cable can assist in the design of a completely new product or in the modification and innovation of an existing system. A tooling inventory we’ve built from decades of hands-on experience in custom cable and wire harness manufacturing carries with it over 5,000 tools for specific and unique shapes, sheathings, mechanical fasteners, overmold connectors, grommets, and strain reliefs to best suit the project’s power, signal, and/or data transference requirements. Better yet, we have the skilled craftsmen wielding these tools with precision matching and sometimes exceeding that of a production machine. However, when volume or precision is absolutely needed, we do employ partially and fully automated solutions. Looking for an in depth guide to wire harness manufacturing? Look no further.
Because our production facilities are 100% owned by Meridian, we have complete control over producing a wide variety of custom options to be employed within a wire harness:
Conductor Sizes and Colors
With state-of-the-art extrusion devices, we are able to extrude conductors down to a size as tiny as 34 gauge and then on up the AWG (32 AWG, 30 AWG, 28 AWG, etc.) to 12 gauge. Different gauges are frequently combined and make up a mixed-gauge cable. We also are able to use a wide variety of different colors, stripes, or dashes on our cables in order to keep track and help further down the line with integration into the system.
Conductors are made up strands, which can be made super small (think 0.002 inches) for unique applications like when high flexibility cable is needed. We can also go the opposite route with a stranding that can be as large as 0.023 inches when just standard power conduction is needed. Most of the time, stranding is bare copper but it can be tinned stranding or even plated with silver when increased conductivity is required.
This is by far the widest category for customization as it encompasses several components of the cable assembly and wire harness design. Conductor insulation, filler materials, wraps, shields, and jackets can all be a unique blend of different materials in order to produce the best result within the environment. For example, specialized materials like Teflon (polytetrafluoroethylene) and Kevlar can be added within these various components to provide abrasion resistance.
UL-Certified Wires and Cables
We choose to use UL-certified cables and wires so that our engineers and design team can hit the ground running at the onset of the project with materials that have known specifications and have been tested across the board. This ensures we don’t waste time trying to figure out safe limits within a custom project and in knowing the components we produced should never fail prematurely. We know the components we produce are utilized in some of the most sensitive environments possible – like in neonatal ICUs, the cockpit of our military’s fighter jets, or the communications satellites that keeps us connected.
Bottom line, Meridian’s customization options abound when it comes to wire harness design. We’ll work with you in order to select the very best components to get the job done on-time and on-budget. Contact our team now to get your project started.
How to Take a Wiring Harness from Concept to Volume Manufacturing
Creating a wire harness is far more than just choosing the right wire harness connectors and terminals. Our planning and design process is incredibly involved because our design team relies on the project plan as a blueprint for guaranteeing a successful product for our clients. Through each stage of the overall manufacturing process, our gifted engineers keep a vigilant eye on the project timeline to ensure all of the necessary components are coming together in the perfect order and at the right moment in the overall sequence. Exploring that process in more detail we see five crucial steps, highlighted in greater detail below:
Design: the very first step in the process requires a frank discussion and a great many back and forths with our clients in order to gain a complete understanding of what all will be required of the wire harness assembly in its given environment. Obviously, we wouldn’t need to construct a wire harness to be used in a military transport vehicle with the same ruggedness as one to be used in an RC car, even though each of these wire harnesses may be carrying out the same mission of electrical, data, or power transmission. Knowing the environment helps dictate the different materials available to combat external threats to the system.
Sourcing: crucial for keeping a project timeline on track, is the necessity of securing the components needed to produce the cable harness assembly. Ensuring the right components are available at just the right time is not an easy task but by ascribing to just-in-time ordering, we’re able to keep the process as efficient as possible.
Prototyping: this important stage allows custom wire harness manufacturers an opportunity to test multiple iterations of the same product simultaneously against one another in order to determine which mix fits best. Different material types will be used in the wire harness assembly and then tested under real life conditions in our advanced testing facilities. By taking the time to do this step early on, we can mitigate against variables that could cost time or money.
Testing: no product ever leaves Meridian’s production line without being tested multiple times for functionality and safety. Sometimes this requires us to have to build out a new testing unit in order to test the unique parameters of a custom wire harness; however, we also regularly employ powerful and exact automated Cirrus testing units, which are considered the industry gold standard. As we just covered, prototyping is an opportunity for several rounds of testing to be knocked out early so that our design team can move forward into production with a specific assembly that’s already been approved in terms of functionality and safety.
Manufacturing: with over 5,000 existing tools available in our large and seemingly ever-expanding tool crib, our manufacturing team has everything required to produce a perfect product within even the strictest project timelines. Kanban methods of lean and efficient manufacturing are ever-present in our manufacturing facilities and is one way we’ve earned our status as a UL-approved manufacturing facility.
A wire harness company worth its weight will approach each of these steps with exacting professionalism, ensuring the proper steps are taken each and every time to produce a product we know for certain is operating as it should. By being fanatical in our approach to quality, we are able to produce a far superior wire harness assembly versus an off-the-shelf option.
Meeting Cable Harness Manufacturing Needs Across Industries
By working with clients in so many different industries, we have developed expertise in being versatile. Our design team is adept at handling the many different variables that inevitably present themselves throughout a project timeline.
Industries for which we are proud to be a wire harness supplier of distinction include:
- Industrial Controls: powering everything from large scale bottling plants, municipal utility systems, and more these industrial control systems are the brains behind highly complex operations that keep our groceries stocked and the water flowing. Wire harnesses provide the infrastructure support needed for the cables and wires to do their job of transmitting power, data, and signal.
- Medical: requiring special components like bio-sensitive jacks and strain reliefs our design team is able to combine the right components to be safe to the patient, useful to the doctors, and overall a great investment in patient care capability by the hospital.
- Telecommunications: keeping our connected world connected, wire harnesses are used in everything from buried cable to communications satellites orbiting the earth. We have the design capability to produce the custom solutions to keep systems talking, around the earth, and beyond.
- Military: helping our men and women in uniform, we are able to design custom wire harness assemblies that meet strict MILSPEC. These components are used in harsh conditions and typically have a higher usage rate compared to other industries so requires specialized material choices like Kevlar.
- Other Industries: from alternative energy facilities to automotive manufacturers needing OEM parts, our team has the expertise, tools, and experience needed to produce a perfect one-of-a-kind solution to perfectly meet the needs of your custom project.
We have experience across industries, quality assurance and quality control measures that exceed industry standards, and design and produce our own products cradle-to-grave. With this level of intimacy comes the assurance that the product you contracted with us to build will be the perfect solution to that complex environment.
Contact our team now to go over your custom wire harness project’s specs.