Wire Harness Assembly

Premium Wire Harnesses Improve
Testing Outcomes and Throughput

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Wires are necessary for electronic assemblies, linking subsystems and allowing easy interface with peripherals through interconnect standards. The intricate nature of printed circuit board assembly (PCBA) production means there are several possible failure points – testing is crucial to determine the correctness and completeness of a design. More than just keeping the wiring system of an electronic system organized, a wire harness assembly simplifies the analysis and troubleshooting of the device. At VSE, we understand the need for precision electronic interconnectivity; for over forty years, we have built PCBAs and wire harness assemblies that marry the discrete sub-products to ensure performance and service life longevity.

PCBA Box Build Production
Design Board layout maintains design intent and maximizes performance with product constraints (size, weight, etc.)
Board Fabrication The bare board materials are processed to produce all PCB features (copper placement, drilled holes, cutouts, etc.)
Board Assembly The bare board is populated with the components that will provide the circuit function and features.
Enclosure Design The enclosure will provide a safe handling method for interacting with the electronic system.
Cable Assembly Cable assembly will bundle groups of wires in a sheath to improve ruggedness, provide extra shielding for twisted pair wires, etc.
Wire Harness Assembly The wire harness will connect the sub-systems of the design with a wiring system that offers both flexibility and testability.

Wire Harness Assembly From an Experienced Electronics Manufacturer

Manufacturing a PCBA requires tremendous precision, and modern systems of even moderate complexity require multiple boards working together. The system is a design milestone independent of the individual sub-products, as the PCBAs and other hardware must all fit and interface within a well-designed enclosure. Despite this critical role, the wire assembly can sometimes be the last part of the system developed. At VSE, electronics manufacturing is part of our DNA – we view a PCBA as a comprehensive and continuous manufacturing process:

Engineering know-how

Our engineering staff reviews and prepares designs for manufacturing (DFM) by analyzing the layout, material procurement, and manufacturability.

Manufacturing expertise

Our manufacturing team is skilled at creating interconnects that support electronic functionality with a neat and orderly fit. The connections meet the rigors of field usage while offering a desired level of flexibility.

System assembly

Our engineering and manufacturing teams have been collaborating to produce cutting-edge electronic devices for over forty years. Our customers need a wire harness as robust as the PCBAs it connects.

Full-system testing

An electronics assembly is as good as its weakest link. From continuity testing to marginal crimps and contacts that aren’t fully seated with mating connections, we examine every wire assembly for completeness and quality.

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Wire Harnesses Built Alongside PCBs, Not As an Afterthought

We’ve cultivated our reputation and business with suppliers at every stage of PCBA manufacturing to benefit our customers by bundling the procurement and production for all of the project’s sub-products. The combined printed circuit board assemblies, the box build of the system enclosure, and the wire harnesses remain under one roof. Design teams won’t have to worry about staging production across multiple sites and manufacturers, so turnaround times remain minimal on time-sensitive jobs. There are additional benefits to realize by including a wire assembly built in tandem with the rest of the electronic system:

A wire harness assembly organizes inter-board connections for ease of testability and long-term reliability.

Support connected PCBAs

The design and manufacture of the PCBA(s) within the box build contribute to seamless, continuous production. Wire harness assembly will take advantage of this DFM process by being actively considered during board layout to maximize the PCBA’s performance.

A one-stop component shop

For turnkey manufacturing solutions or a more à la carte approach, our component selection process keeps design budgetary constraints in mind. High-volume productions can also benefit from reserving a dedicated production space for ongoing manufacturing.

Support connected PCBAs

The design and manufacture of the PCBA(s) within the box build contribute to seamless, continuous production. Wire harness assembly will take advantage of this DFM process by being actively considered during board layout to maximize the PCBA’s performance.

Experts You Can Trust for Your Wire Harness Projects

In large capital equipment with hundreds of interconnects, mislabeled wires, bad terminations, or improperly seated contacts are common causes of many system-level issues. We know you can’t afford the time or expense of these issues, so at VSE, we build your wire harnesses to the highest quality standards. Rely on our technical expertise and experience in the electronics manufacturing industry to bring your project to fruition while exceeding expectations. Contact us today to learn more about how VSE covers all aspects of electronics system integration, including wire harness assembly.

If you are looking for a CM that prides itself on its care and attention to detail to ensure that each PCB assembly is built to the highest standards, look no further than VSE. Contact us today to learn more about partnering with us for your next project.

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