Build It Right. The First Time.
In demanding industries— medical devices, aerospace, renewables, and automation— wire and cable harness assembly performance directly impacts system uptime and reliability. These seven best practices will help ensure your assemblies are built to last, built to spec, and built for results.
1. Know Your Environment
Before choosing materials, document all conditions:
- Temperature
- Humidity
- UV exposure
- Vibration
2. Use Certified Connectors
Connectors are critical failure points. Choose quality:
- MIL‑DTL, IP67 ratings
- Secure mating, tight tolerances, follow manufacturers guidelines and test
Avoid cheap imports—poor contacts cost more in the long run.
3. Balance Shielding and Flexibility
- Braided = strong EMI protection, less flex
- Foil = flexible, lightweight
- Hybrid = best of both
Match shielding to your environment and signal type.
4. Choose the Right Stranding
- Fine-stranded = high-flex applications
- Solid-core = low-loss, long-run power
Stranding impacts durability, ampacity, and bend radius.
5. Prevent Crosstalk
Power and signal lines don’t mix well.
- Separate noisy and sensitive lines
- Use foil barriers or grounded shields
- Follow IPC/WHMA-A-620 layout best practices
Clean layout = clean signal.
6. Add Mechanical Protection
- Heat-shrink boots
- Over-molded junctions
- Strain reliefs and grommets
These touches prevent field failures—and boost durability.
7. Test and Track Everything
Don’t ship it if you haven’t:
- Checked continuity
- Run hipot/insulation resistance
- Labeled and logged test results
Document every step. Your quality system will thank you.
Final Word: Build for the Mission
Your assemblies are only as strong as their weakest point. These best practices help prevent failures before they start. At MAC, we help engineers spec, prototype, test, and build assemblies that perform under pressure—every time.
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