WIRE HARNESS
A wire harness is an organized bundle of individual wires, cables and connectors typically held together by ties, tape, or flexible tubing.
CABLE ASSEMBLY
A cable assembly consists of multiple wires and cables encased in a single outer jacket. They are more durable and provide better protection in harsh conditions.
PentaLogix offers complete wire harness and cable assembly solutions designed to meet the needs of various industries, including automotive, aerospace, medical, industrial, military, telecommunications, and renewable energy. We handle everything from design and prototyping to large-scale production, testing, and quality checks.
WIRE HARNESS AND CABLE ASSEMBLY CAPABILITIES
Design & Engineering
We turn your requirements into detailed CAD designs and build working prototypes.
Wire & Cable Processing
We cut, strip, and prepare single and multi-conductor wires and cables for assembly.
Connector & Terminal Integration
We attach connectors using crimping or soldering for strong, reliable connections.
Labeling & Identification
We clearly mark wires and cables using laser, thermal, and heat-shrink labels.
Testing & Inspection
All assemblies are visually checked and tested for quality and electrical performance (continuity, resistance, hipot) to meet IPC/WHMA-A-620 standards.
Kitting & Logistics
We offer sub-assembly kits and deliver on your schedule with packaging according to your needs.
BENEFITS OF WIRE HARNESSES AND CABLE ASSEMBLIES
Wire Harnesses and cable assemblies offer numerous benefits, especially in environments where protection, organization, and reliability are important.
Improve Organization
Save space and reduce clutter in complex systems.
Improve Safety
Lower the risk of short circuits and electrical fires.
Increase Durability
Lower the risk of short circuits and electrical fires.
Lower Cost Efficiency
Cut down on labor and material waste by bundling wiring into one assembly.
Simplify Installation
Make setup faster and more straightforward, saving time and labor costs.
WIRE HARNESSES APPLICATIONS
Wire harnesses are mostly used in controlled environments where space constraints are tight and protection against vibration, moisture and wear is needed. Common applications include:
Automotive
Wire harnesses are essential in vehicles, connecting key systems such as dashboards, engine compartments, lighting, power windows and doors, steering, and air conditioning. They help keep wiring organized, secure, and protected in high-vibration environments.
Aerospace
Designed for extreme conditions and high reliability, aerospace wire harnesses meet strict military and industry standards like MIL-STD-454 and ITAR. They are used in communication and antenna systems, control panels, and cockpit wiring to ensure performance under demanding conditions.
Industrial Equipment
Wire harnesses organize internal wiring for motors, control panels, and sensors. In automation and robotics, they efficiently route power and control signals through moving parts such as robotic arms and bases.
Consumer Electronics
In compact devices where space and efficiency are critical, wire harnesses manage and protect internal wiring. They are used in printers and copiers to connect print heads, motors, and sensors; in personal computers to bundle power supplies, fans, USBs, and LEDs; and in audio systems to link amplifiers, speakers, and control units.
Medical Devices
Reliability, cleanliness, and safety are critical in medical applications. Wire harnesses connect sensors to processors and displays in monitoring systems, manage power and signals in surgical tools, and provide compact interconnections in wearable or portable devices—linking batteries, sensors, alarms, and displays.
Telecommunications
Wire harnesses are used to route and organize cables for power, data, and signal transmission across network infrastructure. They ensure stable connections and minimal interference in systems such as antennas, RF units, power amplifiers, switches, routers, and servers.
CABLE ASSEMBLY APPLICATIONS
Cable assemblies are essential in environments where durability, signal integrity, and protection from harsh conditions are critical. They ensure secure, reliable, and organized transmission of power, data, and signals across a wide range of systems and industries. Common applications include:
Military and Defense
In military settings, cable assemblies are built to meet extreme demands. Naval and submarine systems require corrosion- and pressure-resistant assemblies for sonar, radar, and navigation. Military communication networks rely on shielded assemblies to maintain signal clarity and reduce electromagnetic interference.
Marine and Outdoor Systems
Cable assemblies used in marine and outdoor environments must withstand saltwater, UV exposure, heavy weather, and mechanical stress. They are used to power and connect navigation, sonar, lighting, battery systems, communication devices, and marine electronics.
Oil and Gas
Cable assemblies play an important role in exploration, drilling, and production. They are designed to operate in extreme conditions, withstand high pressure, temperature, vibration, and exposure to chemicals.
Renewable Energy
Cable assemblies support clean energy technologies by enabling the efficient transfer of power and signals in solar, wind, hydro, and energy storage systems.
| FEATURE | WIRE HARNESS | CABLE ASSEMBLY |
|---|---|---|
| Environment | Internal (controlled) | External or harsh |
| Protection Level | Moderate | High (moisture, EMI, abrasion, etc.) |
| Flexibility | Moderate | High |
| Durability | Moderate | High |
| Common Use Industries | Automotive, Medical, Appliances | Defense, Oil & Gas, Robotics, Marine |
| Customization Complexity | Lower | Higher (jacketing, shielding, etc.) |
| Cost | Lower | Higher |
EQUIPMENT USED
- Wire Cutting & Stripping Machines
- Crimping Machines
- Harness Test Benches
- Heat Shrink Ovens
- Labeling Machines
- Formboards & Assembly Fixtures
ECOCUT 3300 CUTTING MACHINE
The Schleuniger EcoCut 3300 can automatically cut all kinds of material including wire, cable, round material such as tubing, flat ribbon and Glass Fiber Optic (GOF) cable.
It processes wire up to 16 mm² (6 AWG), cuts round material up to 12 mm (0.47") O.D. and cuts flat material up to 100 mm (3.94") wide.
Processing Capabilities
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Flat Cables
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Round cables, profile
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Shrink Tubing
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Thin metallic, nonmetallic sheets
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Tubing
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Wire marking
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Woven fabric
STRIP SERIES B300 STRIPPING MACHINE
The Schleuniger Strip Series B300 stripping machine performs reliable stripping of cables with cross sections from 0.03 to 8 mm2 (32 to 8 AWG).
Material
- Wire
- Solid Wire
- Single- Conductor Cable
- Kapton
- Discrete Wire
- Stranded Wire
- Multiconductor Cable
- PUR
- PVC
- Teflon
- Tefzel
Processing Capabilities
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Discrete Wire Processing
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Full Strip
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Multiconductor Cable Stripping
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Partial Strip
MULTISTRIP 9480 CUT & STRIP MACHINE
The Schleuniger MultiStrip 9480 is a high-performance, fully automatic wire cutting and stripping machine designed for precision and versatility for a variety of wire harness applications.
Material
- • Microtriaxial Cable
- • Buffered Fiber
- • Coated Fiber
- • Wire
- • Solid Wire
- • Duplex Glass Optical Fiber
- • Single-Conductor Cable
- • Single Wire
- • Fiber Ribbon
- • Fiber Optic Cable, Foils, and More
- • Flat Ribbon Cable
- • Flat Material
- • Shielded Cables
- • GOF (Glass Optical Cable)
- • Rubber
- • Rubber Cords / Profiles
- • Kevlar
- • Kevlar Strands
- • Coaxial Cable
- • Discrete Wire
- • Stranded Wire
- • Wire with Special Isolation
- • Multiconductor Cable
- • POF (polymer optical cable)
- • PUR
- • PVC
- • Tubes + Pipes
- • Tubing
- • Teflon®
- • Fiberglass
- • Triaxial Cable
- • Jacketed Flat Cable
Processing Capabilities
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Cut to length
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Full or partial strip left and right
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Jacket and inner conductor stripping
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Multilayer stripping
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Wire marking
CT 60 PNEUMATIC CRIMPING MACHINE
The Schleuniger CT 60 is a pneumatic benchtop crimping machine engineered for high-force, loose-piece crimping applications. It delivers up to 60 kN (6.7 tons) of parallel crimping force, making it suitable for processing a wide range of terminal types and wire sizes.
The quality of the crimp is guaranteed by a full-cycle mechanism that assures that the dies have closed completely before they are reopened.
UNICRIMP 208 CRIMPING MACHINE
The Schleuniger UniCrimp 208 is a high-performance benchtop crimping machine designed for precise and efficient crimping of rear-feed and side-feed banded terminals. With a crimping force of 33 kN (3.3 tons), it accommodates a wide range of wire sizes and terminal types, making it ideal for various wire harness assembly applications.
Processing Capabilities
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Discrete wire crimping
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Multiconductor cable crimping
STRIPCRIMP 208 STRIPPING MACHINE
The Schleuniger StripCrimp 208 stripping machine combines the standard working processes of cable processing in a single machine. Short breakout lengths of 22 mm (0.86") and even down to 10 mm (0.39") using special tools permit the processing of sensor applications.
Processing Capabilities
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Discrete wire crimping
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Discrete wire stripping
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Discrete wire stripping & crimping
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Multiconductor cable crimping
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Multiconductor cable stripping
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Multistep stripping
COAXSTRIP 6480 STRIPPING MACHINE
The semiautomatic Schleuniger CoaxStrip 6480 stripping machine processes coaxial cables with an outer diameter of 1.2 to 12 millimeters.
It is equipped with "cable end detection" and "cable diameter verification."
WTT WIRE TERMINAL PULL TESTER
The WTT Wire Terminal Pull Tester is designed to test the pull-out force of crimped wire terminals. It features a digital display for accurate force measurement and can be used for quality control in wire harness production.
The tester helps ensure that crimped connections meet required specifications and industry standards for pull-out strength.