Wire Harness and Cable Assembly
What Is a Wire and a Cable
A wire is a single strand of conductive material such as copper, aluminum, or tin.
A cable, on the other hand, consists of two or more wires bundled together, often braided or bonded.
What Is a Wire Harness and Cable Assembly
✅ Wire Harness
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A simple outer sheath that holds together wires or cables.
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Usually made from thermoplastic or thermoset material to provide basic protection.
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Ideal for organizing internal wiring in controlled environments.
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Limitations: Not designed to withstand extreme temperature, friction, or moisture.
✅ Cable Assembly
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A more rugged, protective casing that encloses wires or cables.
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Typically made from heavy-duty materials like vinyl or thermoplastic rubber.
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Designed for harsh environments: heat, moisture, abrasion, vibration, etc.
Key Differences Between Wire Harness and Cable Assembly
Application Environments
| Feature | Wire Harness | Cable Assembly |
|---|---|---|
| Usage | Internal use (PCs, electronics) | Industrial or outdoor applications |
| Conditions | Stable, dry, enclosed | Harsh: dust, oil, temperature swings |
| Space Constraints | Flexible, compact design | Custom sizes and robust builds |
Structure & Materials
| Feature | Wire Harness | Cable Assembly |
|---|---|---|
| Sheath | Light plastic or rubber wrap | Heavy-duty thermoplastic or vinyl |
| Layers | Thin external sheath over pre-insulated wires | Fully enclosed, high-strength structure |
| Cost | Low-cost solution | Higher cost, more robust |
Durability
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Wire Harness: Limited durability; suitable for low-risk environments.
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Cable Assembly: High durability; resists heat, pressure, moisture, and mechanical stress.
PCB Wire Harness Applications
🟢 PCB Wire Harness
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Connects printer heads to the mainboard.
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Also used in scanners, copiers, plotters, audio systems, IoT devices, etc.
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Ensures stable signal transmission in modern electronics.
🔵 PCB Data Wire Harness
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Built with pure copper core and quality plastic insulation.
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Designed to transmit data signals within electronic and electrical devices.
🔴 PCB Power Wire Harness
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Equipped with precision copper terminals and flame-retardant sheaths.
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Connects AC power to PCBs via:
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U-shape / O-shape terminals
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Fast-plug connectors
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One end is soldered to the PCB; the other may have a terminal.
What Can Fully Hong Electronics Do for Your Wire Harness & Cable Assembly
Fully Hong Electronics specializes in PCB fabrication and assembly, including custom wire harness and cable assembly services.
Our Strengths:
✅ Reliable supply of UL-certified cables and wires
✅ Cost-effective sourcing through a strong global supply chain
✅ Skilled engineers and advanced equipment
✅ Capable of assembling simple to complex wire harness systems