A wire harness can be simple, two wires with basic terminals on the end, or a complex web of many conductors with a variety of connectors and terminations. In addition, wire harnesses often need special shapes, sheathing, mechanical fastening and over molded connectors, grommets or strain reliefs. Meridian Cable can assist in the custom wire harness design or quote your existing wire and cable harness design. Our wholly owned manufacturing facilities include our China location, which is UL approved for wire harness manufacturing, and our US location. We’re ready to help solve your cable assembly and wire harness needs.
- We have a full complement equipment to process wire harness, from basic hand tools to semi-automatic machines to fully automated systems, depended on the accuracy needed.
- We have an extensive tool crib that covers most terminal manufacturers.
- Fine pitch, computer controlled soldering.
- Multi cable wrapping or sheathing.
- Ultrasonic welding.
- Over molding for connectors, strain reliefs, grommets.
- Programmable, automated test equipment.
- Automated wire cutting equipment capable of handling a wide range of wires and cables.
We can extrude conductors as small as 34 gauge and as large as 12 gauge. These can be combined to create a mixed gauge cable.
- 34 awg
- 32 awg
- 30 awg
- 28 awg
- 26 awg
- 24 awg
- 22 awg
- 20 awg
- 18 awg
- 16 awg
- 14 awg
- 12 awg
Meridian’s custom wire and cable harness capabilities are extensive, from 1 conductor to cables with more than 50 conductors. Custom colors, striping and marking are available to meet your wiring harness design requirements.
Your conductors can be made with stranding as small as 0.002 inches (0.05mm) which is excellent for hi-flex, supple cables. If you just need a standard power conductor we can use stranding as large as 0.01 inches (0.25 mm). Stranding can be bare copper, tinned stranding, tinned conductor or even plated with precious metals such as silver for increased conductivity.
The first protection in any cable is the conductor’s insulation. Meridian’s wire and cable extrusion capabilities include a wide range of materials to match your requirements for flexibility, abrasion resistance and environmental conditions. We use the range from basic PVC, PE or PP. We also use insulating materials such as natural rubber, PU, TPE, PTFE (Teflon®) and silicone.
- Polyvinylchloride (PVC)
- Polyurethane (PU)
- Thermoplastic elastomer (TPE)
- Thermoplastic polyester elastomer (TPEE)
- Thermoplastic vulcanizate (TPV)
- Polytetrafluoroethylene (Teflon®)
UL® Certified Wire & Cable
There are many standard UL® cable types. UL® standards help designers choose a cable with known specifications instead of creating one from scratch. We are certified by UL® to produce many standard types of wire and cable harnesses.
These can be modified for color and stripping and still be UL certified.
Wire Harness Manufacturer FAQs
Get information on how Merdian Cable Assemblies creates a custom wire harness. We supply wire harnesses all over the USA and answer the most commonly asked questions from how we create a custom wire harness to fit your needs to providing information on what wire harness manufacturers actually do. Read on for more information and feel free to contact us directly for any questions that you might have.
Wire harness manufacturing entails creating a custom set-up of electrical wires and/or cables based on the task needed by our client. You can imagine this can run a pretty large gambit of different applications. As custom wire harness manufacturers, it is our job to fully understand the client’s needs, examine where the cable harness will be used, and consider a host other factors that determine the material types and attributes needed for the wiring harness to perform under even the harshest of conditions for years of faithful, continued service. At Meridian, we have the tools and experience to create just about any wiring harness application a client can think of. We usually produce a small number of prototypes to ensure our engineers have everything perfect for the unique application our client is intending before we move on to larger-scale production.
Wiring harnesses are used in everything from remote control cars to jumbo jets. For example, the desktop computer you may be using currently has a myriad of different harnesses for data and power transfer, all to let you view a page like this one. Inside your vehicle are reams of cables, wires, terminals, and connectors that have to run through the entire vehicle in order to connect all the different components that allow you to simply drive from A to B. The harness itself sounds simple, but it can be rather complex when different connections, terminations, conductor sizes, sheathing, strain reliefs, and many other considerations have to come into play depending on the needs of the project. Our engineers design a complete system around the wires and cables needed to power electrical systems, transfer high speed data, and send and receive signals. If you’re ready to discuss your project’s unique requirements, talk over your options with a knowledgeable representative now.
The different types of wiring harnesses is only limited by your imagination. As we continue to increase our reliance on electrical systems powering even simply devices, the engineering inside of these applications requires custom made wiring and cable harnesses to complete the intended application. Each project requires its own custom set-up in order to be designed and manufactured to be able to effectively complete the task required of it. As you can imagine, this will be quite different for a remote control car versus a fighter jet, yet each require exact engineering design in order to function. From military applications, industrial, medical, telecommunications, and almost every industry in between, we design custom wire harness solutions that work.
Definitely not. Unfortunately, shoddy manufacturers abound and buying a harness from a non-reputable wiring harness supplier can put your project’s assets at serious risk of failure. At Meridian, we follow strict quality assurance/quality control procedures, use and maintain UL® standards for wiring, and are proud to have received and maintain ISO 9001:2015 certification for quality. We do all of this to ensure we remain wire harness and cable assembly manufacturers of distinction, engineering the precise solutions our clients demand, and making sure these systems are robust enough to stand up to years of use.
We strive to make sourcing cable assemblies and wiring harnesses easy. That’s why we operate two manufacturing facilities both in the U.S. and in China. We own both facilities, so we stay intimately abreast of the day-to-day operations of each. We are UL®-approved for wire harness manufacturing so you can be confident in the exact requirements of your project being met by our design staff. With two, independent facilities running around the globe, we ensure your project is completed on-time and on-budget, using the best materials and methods available in wire harness manufacturing today. So no matter where your project takes place, be confident knowing Meridian can supply all the components needed to produce a top-of-the-line custom cable harness.
For any custom cable or wire harness project, our engineers and design staff first listen to our clients. By intimately understanding the “what, when, where, and how” behind the harnesses’ intended application, we can begin the manufacturing process. Often, we need to understand the electrical needs, as well as, the space constraints first and foremost and build our systems within the project’s scope concerning these dimensions. Each process is a little different for each custom harness and Meridian craftsmen have more than 5,000 tools at their disposal to get the job done. Depending on the level of precision the project calls for, we can either deploy hand tools, semi-automated machines, or fully automated machines. Even though we depend on automation to provide exact design specifications, a lot of work is still done by hand by our skilled manufacturers due to the multitude of complex steps involved. Our process engineers deploy time and money savings techniques like kanban manufacturing and just-in-time ordering to provide the very best products possible, on-time, and within our client’s budget.
After we’ve figured out the ins and outs of the project’s unique manufacturing process, we usually develop a prototype for client approval and verification that it will meet their needs. Once approved, we move to larger scale production and ship our products to clients all over the world.
United Laboratories (UL) is one of only a select few corporations that have been approved by the U.S. Occupational Safety and Health Administration (OSHA) for testing and certifying both safety and uniform functionality of wiring and cable components. By only using UL-certified components, we can ensure our products operate the same way, within known specification ranges, year in and year out. Rather than having to design a cable from scratch each time, this allows design staff to focus on other project variables such as weight strain reduction within the harness, type and size of conductors, insulation material, etc. If you don’t see that your wire harness and cable assembly manufacturers are using UL-certified wires and cables, don’t trust your integral electrical systems to a system which could fail when you need it the most.
These often confused components are quite different and serve different purposes. A wire is either a single strand or a bundle of strands that are designed to be conductive. Wires come bare or sheathed and are usually made of copper or aluminum. Conversely, a cable has two or more conductors which are insulated which are then twisted together, usually inside of a protective outer jacket. A wire harness therefore, is the systematic support system that links wires into a cohesive unit with the necessary connections and terminations to complete the task. Think the wiring system in your automobile that requires different systems to all be linked simultaneously. While a cable assembly is similar in concept, the application is quite different and would include examples like the fairly simple cable assembly for connecting your TV and surround sound or the more complex and futuristic-looking electrode helmets used in medical brain scans.
The International Organization for Standardization (ISO) specifies the minimum requirements that the quality assurance/quality control plans a manufacturer has to have in place in order to be certified for ISO 9001:2015. For this system governing quality management systems, the organization needs to show that it has the ability to consistently deliver the products or services that meet both customer and regulatory requirements, as well as, show they’ve taken steps to enhance the customer’s satisfaction. This is done through demonstrating the organization has continual improvement processes in place and can showcase conformity to customer/regulatory requirements for each project undertaken. Meridian is proud to maintain this important distinction for ensuring our clients receive nothing but high-quality products.
Meridian designs products under the strictest of quality assurance and quality control guidelines, but components do sometimes break down prematurely. We want you to be absolutely confident in your decision to use Meridian as your wire harness supplier of choice so we stand behind our products with a warranty against material defects or workmanship under normal use and service for a period of one (1) year from the original date of invoice. Depending on the situation, Meridian will either repair or replace the product.
Wire Harness Guides & Resources
- The Ultimate Wire Harness Connectors Guide
- The Ultimate Guide to Wire Gauge Sizes | Learn What Gauges Are Used For Custom Wire Harness Applications
- The Benefits of Low Pressure Molding in Wire Assembly
- The Cable Engineer’s Ultimate Heat Shrinking Tubing and Sleeves Guide
- Advantages of Having a Full Tooling Inventory in Cable Production and Assembly