# H&L Manufacturing — complete site content > Family-owned contract manufacturer in Middleville, Michigan since 1967. > This file contains the full text content of every page on https://hlmanufacturing.com. > A concise index is at https://hlmanufacturing.com/llms.txt. --- # About H&L Manufacturing | Family-Owned Since 1967 URL: https://hlmanufacturing.com/about Description: H&L Manufacturing — family-owned contract manufacturer since 1967. Wire harness assembly, overmolding, and general assembly in Middleville, Michigan. Est. 1967 — Middleville, Michigan # About H&L Manufacturing Since 1967 — a family-owned contract manufacturer rooted in quality, innovation, and continuous improvement. 01 History ## Our Story H&L Manufacturing got its start in Caledonia, Michigan in 1967 under the ownership of Larry and Lila Alkema. In 2005, the Alkemas passed the torch to Steve Sawdy, who continued to grow the business. In 2011, H&L relocated from its 20,000 sq ft facility in Caledonia to the current 54,000 sq ft facility in Middleville, Michigan — nearly tripling their production space and enabling them to take on additional new business that simply wouldn't have fit in the old facility. In 2017, Steve brought added expertise to the business to accelerate growth. Jeff Gillesse and Russ Richardson joined H&L as partners, bringing new strength in finance and lean manufacturing. The team has since driven a culture of continuous improvement — investing heavily in automation, vision systems, custom tooling, and employee development. 900 E Main St, Middleville — Beyond Your Expectations 02 How We Work ## A Culture of Continuous Improvement H&L has assembled a dedicated continuous improvement team that evaluates current technology, identifies areas of deficiency, and devises creative solutions. Rather than buying expensive off-the-shelf equipment, the team frequently engineers and fabricates custom machines in-house — achieving the same results at substantially lower cost. The company invested significantly in enhancing design capability, including CNC milling equipment, upgraded CAD software, and additional training for technical staff. “The tech guys were busy on the floor reacting to problems, but nobody was focused on solving them. We took them out of that situation, and now they are solving problems.” — Russ Richardson One standout innovation was the addition of vision systems to improve quality. After analyzing quality complaints, the team found that roughly 45% of issues could be eliminated through error-proofing on the detection side. Vision cameras are installed directly over assembly fixtures, taking a snapshot of every part to verify correct location and orientation before it's released. The system ties directly into continuity testing — a part doesn't move until the vision system says it's OK. “We're not implementing anything going forward without this technology, so we're all in,” Russ confirmed. Through these continuous improvement efforts, H&L has improved efficiency while growing sales — a testament to working smarter, not just harder. Most recently, H&L has begun integrating artificial intelligence into its operations — partnering with tools like Claude to streamline RFQ processing, enhance sales workflows, and improve efficiency across the organization. It's the latest step in H&L's commitment to being forward-thinking pioneers in the contract manufacturing industry, always looking for the next edge that benefits both the company and its customers. 03 Positioning ## What Makes H&L Unique “We don't create noise for our customers. We are an insurance policy for them — we have great quality systems and deliver great performance, so they don't really have to worry about us.” — Russ Richardson H&L regularly invites customer teams to participate in kaizen events, showing stakeholders firsthand how processes are being improved to reduce their downside risk. For the H&L team, it's about common-sense problem solving. “There might be an expensive machine you can buy to solve a problem, but is there something simple you can do to keep the cost low?” That practical, engineering-driven mindset runs through everything H&L does — from custom continuity testing blocks built in-house to purpose-built taping machines designed for long-term reliability. 04 Timeline ## Company Milestones - 1967 Founded in Caledonia, MI by Larry and Lila Alkema. - 2005 Steve Sawdy takes ownership and continues growing the business. - 2011 Relocated from 20,000 sq ft facility in Caledonia to 54,000 sq ft facility in Middleville, MI. - 2017 Jeff Gillesse and Russ Richardson join as partners, adding expertise in finance and lean manufacturing. - 2018 Invested significantly in capital improvements — vision systems, Arburg overmolding machines, custom tooling, and facility upgrades including facility-wide air conditioning. - Today Full-service contract manufacturer with wire harness, overmolding, 3D printing, and assembly capabilities — serving automotive, marine, heavy equipment, and more. 05 Mission ## Our Mission “To provide a product and service that goes beyond our customer's expectation.” Our Shared Values 01 ### Respect We have as much consideration for the personal and professional worth and dignity of others as we do for ourselves. 02 ### Initiative We are willing and empowered to proactively contribute to the success of the company, its customers, and other employees. 03 ### Accountability We are responsible for our own actions and answerable to others. 04 ### Excellence We give our personal best. 05 ### Integrity We maintain high ethical and moral standards in speech and in personal and professional conduct. 06 ### Innovation We seek out new possibilities in every area and embrace ground-breaking change that adds value. 06 Team ## Leadership ### Steve Sawdy Partner & President Took ownership of H&L in 2005, continuing the family legacy and driving facility expansion and employee investment. ### Russ Richardson Partner & CEO Joined H&L in 2017, bringing deep expertise in lean manufacturing and leading continuous improvement and automation initiatives. ### Jeff Gillesse Partner & CFO Joined H&L in 2017, strengthening financial strategy and driving selective, profitable growth. ## Partner With H&L Let's discuss how we can support your manufacturing needs. Contact Us → --- # Press & Media | H&L Manufacturing URL: https://hlmanufacturing.com/about/press Description: Industry coverage and media features highlighting H&L Manufacturing's innovation, growth, and leadership in contract manufacturing. About / Press # Press & Media Industry coverage and media features highlighting H&L Manufacturing's innovation, growth, and leadership in contract manufacturing. 01 Wiring Harness News — July 2025 ## Featured Article ### H&L Manufacturing: Reinvention Through Ingenuity and Intentionality A deep-dive feature revisiting H&L Manufacturing seven years after their first profile. The article explores the company's dramatic transformation — from proprietary engineering breakthroughs and strategic diversification away from automotive, to cutting-edge automation built entirely in-house. Key Highlights - 01 Shifted from 90%+ automotive to under 30%, focusing on higher-value industrial partnerships - 02 Acquired nine 3D printers running near full-time for prototyping and production - 03 Designed and built proprietary spot tape machines — nothing like them exists on the market - 04 Grew engineering team to eight — most developed in-house without traditional degrees - 05 Improved throughput significantly through automation and lean manufacturing - 06 Achieved seven consecutive months with zero customer complaints and ~10 PPM - 07 Invested significantly in equipment while raising wages across the board Read Full Article → 02 In Their Words ## From the Article “ We were quoted a half million to automate that line. We did it ourselves for a fraction of the cost. ” — Russ Richardson, CEO “ We have people without college degrees who are doing high-level engineering work and getting paid accordingly. That's been the really exciting thing. ” — Jeff Gillesse, CFO “ We can't brag on our employees enough. Our staff is just phenomenal — from production to management. Most of our team has come up through the ranks. ” — Steve Sawdy, President “ We went seven months without a single customer complaint. Our PPM is around 10. That's unheard of. ” — Jeff Gillesse, CFO 03 Wiring Harness News — July/August 2018 ## Earlier Coverage ### Company Profile: H&L Manufacturing The original feature that introduced H&L to the Wiring Harness News readership. The article profiles the company's history from its 1967 founding through the 2017 ownership expansion, and spotlights the lean manufacturing culture, in-house engineering innovations, and aggressive growth strategy that would define H&L's trajectory. Key Highlights - 01 Invested significantly in capital improvements including Komax, Artos automation and facility-wide air conditioning - 02 Added vision systems with a 4.5-month ROI — eliminating 45% of quality issues through error-proofing - 03 Built custom continuity testing blocks and taping machines in-house at a fraction of commercial cost - 04 Improved efficiency through lean manufacturing while maintaining higher sales - 05 Launched marketing push to diversify from 98% automotive toward marine, fire trucks, and heavy equipment - 06 Invested significantly in CNC milling, CAD software, and technical staff training for design capability Read Full Article → ## Want to Learn More About H&L? Discover how our innovation and quality can support your manufacturing needs. About H&L → Contact Us → --- # Accessibility Statement | H&L Manufacturing URL: https://hlmanufacturing.com/accessibility Description: H&L Manufacturing's commitment to digital accessibility and WCAG 2.1 Level AA conformance. Legal # Accessibility Statement Our commitment to digital accessibility ## Our Commitment H&L Manufacturing is committed to ensuring digital accessibility for people with disabilities. We continually improve the user experience for everyone and apply the relevant accessibility standards. ## Conformance Status We aim to conform to the Web Content Accessibility Guidelines (WCAG) 2.1 Level AA. These guidelines explain how to make web content more accessible for people with disabilities and more user-friendly for everyone. ## Measures Taken - Semantic HTML structure throughout the site - Descriptive alt text on images - Sufficient color contrast ratios - Keyboard navigable interface - ARIA labels where appropriate - Responsive design for all device sizes ## Feedback We welcome your feedback on the accessibility of our website. If you encounter accessibility barriers or have suggestions for improvement, please contact us: - Email: info@hlmanufacturing.com - Phone: 269-795-5000 - Address: 900 East Main Street, Middleville, MI 49333 We aim to respond to feedback within 5 business days. --- # Contact H&L Manufacturing URL: https://hlmanufacturing.com/contact Description: Get in touch with H&L Manufacturing. Phone, email, or visit our Middleville, Michigan facility. 269-795-5000. Get In Touch # Contact Us Get in touch with our team. For quote requests, use our dedicated RFQ form for the fastest response. 01 Message ## Send Us a Message Full Name * Email Address * Phone Number Your Message * Send Message → 02 Details ## Contact Information Address 900 East Main Street Middleville, MI 49333 Phone 269-795-5000 Email info@hlmanufacturing.com Hours Monday – Friday 6:30 AM – 3:00 PM EST Social LinkedIn Facebook Facility — 900 E Main St, Middleville, MI 49333 --- # Disclaimer | H&L Manufacturing URL: https://hlmanufacturing.com/disclaimer Description: Legal disclaimer for H&L Manufacturing's website. Important information about quotes, pricing, and liability. Legal # Disclaimer Important legal information ## General Disclaimer The information provided on this website is for general informational purposes only. While H&L Manufacturing strives to keep the information up to date and accurate, we make no representations or warranties of any kind, express or implied, about the completeness, accuracy, reliability, suitability, or availability of the information, products, services, or related graphics contained on the website. ## Quotes & Pricing All quotes provided through this website are estimates and subject to change based on final specifications, materials availability, and volume. Formal pricing is governed by H&L Manufacturing's Terms & Conditions . H&L Manufacturing reserves the right to adjust prices for changes in material costs or labor rates between the date of quotation and the date of shipment. ## Product & Service Information Descriptions of services, capabilities, and specifications on this website are provided for reference only. Actual capabilities, lead times, and deliverables may vary based on project requirements. All orders are subject to H&L Manufacturing's standard Terms & Conditions. ## External Links This website may contain links to external sites. H&L Manufacturing does not control the content of these sites and is not responsible for their content or availability. ## Limitation of Liability In no event shall H&L Manufacturing be liable for any loss or damage, including without limitation, indirect or consequential loss or damage, arising from the use of this website. All manufacturing agreements are governed by our Terms & Conditions . ## Governing Law This website and any disputes arising from its use are governed by the laws of the State of Michigan, without giving effect to conflict of laws principles, with jurisdiction in Barry County, Michigan. --- # H&L Manufacturing | Wire Harness & Contract Manufacturing URL: https://hlmanufacturing.com/ Description: H&L Manufacturing — custom wire harness assembly, overmolding, control panels, and general assembly. Family-owned since 1967 in Middleville, Michigan. ISO 9001:2015 certified. Middleville, Michigan — Family-Owned Since 1967 # Precision Wire Harness Manufacturing & Contract Assembly From prototype to production — wire harnesses, overmolding, control panels, and assemblies built in Middleville, Michigan. Request a Quote → Explore Capabilities → 0 + Years in Business 0 K+ Sq Ft Facility 0 % Continuity Testing 0 3D Printers 01 Capabilities ## What We Build Comprehensive contract manufacturing capabilities under one roof. 01 ### Wire Harness Manufacturing Custom wire harnesses engineered and built to your exact specifications. From single prototypes to high-volume production runs. Learn More → 02 ### Overmolding Durable, sealed overmolded connectors and assemblies for harsh environments. Custom tooling and material selection. Learn More → 03 ### Control Panel Assembly Complete control panel builds including wiring, component mounting, labeling, and testing. Learn More → 04 ### General Assembly Box builds, sub-assemblies, kitting, and turnkey assembly services. We handle production so you can focus on your product. Learn More → 05 ### Prototyping Rapid prototype builds to validate your design before committing to production. Fast turnaround and engineering feedback included. Learn More → 06 ### 3D Printing Additive manufacturing for fixtures, jigs, enclosures, and test blocks. Supports your wire harness and assembly projects. Learn More → 02 The H&L Difference ## Why Manufacturers Choose H&L 01 ### Vertically Integrated Wire harness, overmolding, panel assembly, and 3D printing under one roof. One vendor, zero handoff delays. 02 ### American Made Manufactured in Middleville, Michigan. Shorter lead times, no offshore communication barriers, full IP protection. 03 ### Prototype to Production Start with a single prototype and scale to thousands without switching vendors. We grow with your program. 04 ### Quality Obsessed Every harness is tested. Every assembly is inspected. Professional workmanship standards guide everything we build. 03 Markets ## Industries We Serve Automotive Consumer & Commercial Products RV & Recreational Utility Trailers & Vehicles Industrial Controls & Automation Agriculture & Heavy Equipment 04 FAQ ## Frequently Asked Questions Common questions about H&L Manufacturing and our capabilities. 01 What does H&L Manufacturing do? + H&L Manufacturing is a full-service contract manufacturer specializing in wire harness assembly, overmolding, control panel builds, general assembly, and prototyping — all from our facility in Middleville, Michigan. 02 Where is H&L located? + We're located at 900 E Main St, Middleville, MI 49333. Our 54,000+ square foot facility houses all of our manufacturing capabilities under one roof. 03 How long has H&L been in business? + H&L has been serving manufacturers for over 59 years, building a reputation for quality, reliability, and on-time delivery since day one. 04 What industries do you serve? + We serve automotive, consumer & commercial products, RV & recreational, utility trailers & vehicles, industrial controls & automation, and agriculture & heavy equipment industries. 05 Can you handle both prototypes and production runs? + Absolutely. We support everything from single prototype builds to high-volume production runs — and you never need to switch vendors as your program scales. 06 What quality standards does H&L follow? + We follow IPC/WHMA-A-620 workmanship standards. Every wire harness is electrically tested and every assembly is inspected before it ships. 07 Do you offer overmolding services? + Yes. We provide custom overmolding for connectors and assemblies, ideal for harsh environments requiring sealed, durable connections. We handle tooling design and material selection. 08 What is your typical lead time? + Lead times vary by project complexity and volume. Prototypes can often be turned around in days, while production orders are scheduled based on your delivery requirements. Contact us for a specific timeline. 09 How do I request a quote? + Simply visit our Request a Quote page and upload your drawings, specs, or BOM. Our team will review your project and respond with a competitive quote. 10 Are you hiring? + Yes! We're actively hiring for 1st shift production positions. We offer a clean facility, great culture, and room to grow. Visit our Careers page to see open positions. Now Hiring — 1st Shift ## Join Our Team We're hiring for 1st shift production positions. Clean facility, great culture, room to grow. View Open Positions → ## Ready to Discuss Your Next Project? Send us your drawings and specs — we'll get back to you with a competitive quote. Get a Quote → --- # Industries We Serve | H&L Manufacturing URL: https://hlmanufacturing.com/industries Description: Wire harness and contract manufacturing for automotive, industrial, marine, agriculture, and consumer products. Middleville, Michigan. Markets # Industries We Serve Trusted by manufacturers across industries that demand precision, reliability, and quality. 01 ## Automotive We supply audio component wiring, rear camera harnesses, deck lid and spoiler applications, heated diesel fuel hoses, and side-view mirror harnesses. Deep OEM experience and high-volume capability. Key capabilities OEM-spec connectors Heat-resistant materials High-volume production 02 ## Consumer & Commercial Products Assemblies for fire truck manufacturers, food trucks, small appliances, and consumer products. Scalable production with consistent quality. Key capabilities Scalable production Cost optimization Quick-turn capability 03 ## RV & Recreational Wire harnesses for recreational vehicles and marine applications including trolling motors and lighting for small boats. Built to withstand harsh conditions. Key capabilities Marine-grade wiring Environmental sealing Durable assemblies 04 ## Utility Trailers & Vehicles Rugged wire harnesses for utility trailers and vehicles operating in harsh environments — dust, moisture, vibration, and extreme temperatures. Key capabilities Waterproof connectors Heavy-gauge wiring Vibration-resistant assemblies 05 ## Industrial Controls & Automation Control panel assemblies, power cords, and sensor harnesses for factory automation. Assemblies for distribution power conveyors and industrial equipment. Key capabilities Control panel assembly Sensor harnesses UL compliance 06 ## Agriculture & Heavy Equipment Rugged wire harnesses for agricultural and heavy equipment applications operating in demanding field conditions. Key capabilities Waterproof connectors Heavy-gauge wiring Vibration-resistant assemblies ## Don't See Your Industry? We work across many verticals. Reach out and let's discuss your application. Request a Quote → --- # Careers at H&L Manufacturing | Join Our Team URL: https://hlmanufacturing.com/jobs Description: Build your career at H&L Manufacturing. Hiring for 1st shift production positions in Middleville, Michigan. Now Hiring — 1st Shift Only # Build Your Career at H&L Join a team where your work matters, your growth is invested in, and your contributions are recognized. We're hiring for 1st shift only — no nights, no rotating schedules. Apply Now → Learn About H&L → 01 Benefits ## Why People Choose H&L This isn't just a job — it's a place where you can grow, learn, and make a real impact. 01 ### Promote From Within Almost every manager and lead at H&L started in production. Your growth path isn't capped — it's encouraged. 02 ### Work With Cutting-Edge Tech Vision systems, CNC milling, 3D printing, AI-powered workflows — you'll work alongside technology that's reshaping manufacturing. 03 ### Family-Owned Culture Since 1967, H&L has been family-owned. That means decisions are made by people who care, not a faceless board. 04 ### Clean, Climate-Controlled Facility Our 54,000 sq ft Middleville facility is air-conditioned and well-maintained — not your typical shop floor. 05 ### Stability & Security 59+ years in business serving automotive, marine, and industrial customers. This isn't a startup — it's a company with staying power. 06 ### Values-Driven Workplace Respect, initiative, accountability, excellence, integrity, and innovation aren't just words on the wall — they guide how we operate daily. “We took the tech guys out of reacting to problems and put them in a position to solve them. That's what continuous improvement looks like.” Russ Richardson — CEO & Partner 02 Day To Day ## What to Expect 01 ### Hands-On Manufacturing You'll work 1st shift only in wire harness assembly, overmolding, control panels, and more — building real products for real customers in automotive, marine, and industrial markets. 02 ### Training & Development H&L invests significantly in design capability, CNC equipment, CAD software, and staff training. You'll learn skills that advance your career. 03 ### Problem-Solving Culture Our continuous improvement team doesn't just buy expensive machines — they engineer creative, cost-effective solutions. Your ideas matter here. 04 ### Equal Opportunity Employer H&L Manufacturing is an Equal Opportunity Employer. We welcome applicants of all backgrounds. ## Ready to Join the Team? Complete our online application — it only takes a few minutes. Start Your Application → --- # Apply Now | H&L Manufacturing Careers URL: https://hlmanufacturing.com/jobs/apply Description: Complete our online application for production positions at H&L Manufacturing in Middleville, Michigan. Careers — Application # Online Application A thorough understanding of your experience and qualifications will assist us in placing you in the right position. - 1 Personal Info - 2 Availability - 3 Background - 4 Education - 5 Employment - 6 Review ## Personal Information First Name * Last Name * Phone Number * Email Address Street Address * City * State * ZIP * ### Emergency Contact Contact Name * Contact Phone * ### Resume (optional) Upload your resume PDF, DOC, or DOCX — max 5 MB ← Back Next → --- # Privacy Policy | H&L Manufacturing URL: https://hlmanufacturing.com/privacy-policy Description: H&L Manufacturing's privacy policy. How we collect, use, and protect your personal information. Legal # Privacy Policy Last updated: February 9, 2026 ## Information We Collect When you submit a quote request, contact form, or job application through our website, we collect the personal information you provide, including your name, company name, email address, phone number, and job title. We may also collect files you upload such as drawings, BOMs, and specifications. ## How We Use Your Information - To respond to your quote requests and inquiries - To process and fulfill orders - To communicate with you about your projects - To improve our website and services - To comply with legal obligations ## Information Sharing We do not sell, trade, or rent your personal information to third parties. We may share information with trusted service providers who assist in operating our website or conducting our business, provided they agree to keep this information confidential. ## Data Security We implement reasonable security measures to protect your personal information. All drawings, specifications, and technical material submitted to H&L Manufacturing remain your property and are kept confidential, as outlined in our Terms & Conditions. ## Cookies Our website may use cookies and similar technologies to enhance your browsing experience and analyze site traffic. You can control cookie preferences through your browser settings. ## Your Rights You may request access to, correction of, or deletion of your personal information by contacting us at info@hlmanufacturing.com or calling 269-795-5000 . ## Changes to This Policy We reserve the right to update this policy at any time. Changes will be posted on this page with an updated revision date. ## Contact H&L Manufacturing Co. 900 East Main Street Middleville, MI 49333 info@hlmanufacturing.com 269-795-5000 --- # Quality & Certifications | H&L Manufacturing URL: https://hlmanufacturing.com/quality Description: ISO 9001:2015 certified, UL Approved, IPC/WHMA-A-620 compliant. Every harness 100% tested. Middleville, Michigan. Zero-Defect Mindset # Quality & Certifications We strive for zero defects, both in production and shipping. 01 Approach ## Quality Philosophy At H&L Manufacturing, quality is embedded in every step of our process — from design review through final inspection and shipping. Our systems are built to meet customer expectations in PPAP, APQP, Delivery and Price. We have a strong Engineering team to assist our customers up front in design and offer potential ideas to help reduce costs. Every wire harness is 100% continuity and short tested with integrated vision systems before leaving our facility. Standards & Certifications ### ISO 9001:2015 Quality management system certified by Intertek. Status: Certified ### UL Approved UL Approved Wire Harness Manufacturer. Status: Approved View ISO 9001:2015 Certificate → 02 Verification ## Testing Capabilities - 01 EOL Continuity / Short Testing with Integrated Vision Systems - 02 Crimp Force Monitoring - 03 Wire / Terminal Cross-Section Analysis - 04 Pull testing for crimp terminations - 05 Visual inspection - 06 Functional testing per customer specs 03 Recognition ## Customer Awards Year Customer Award 2014 Webasto Quality Excellence Award & Cost Competitiveness Award 2015 Webasto Best In Class Award 2019 Alpine Electronics Supplier of the Year 04 Measured Continuously ## Key Performance Indicators The metrics our quality system tracks and reviews to hold ourselves accountable. KPI 01 On-Time Quote KPI 02 On-Time APQP KPI 03 Premium Freight KPI 04 Supplier QA-Line Disruption KPI 05 Lost Time Injuries KPI 06 Safety Audits (Quarterly) KPI 07 External PPM KPI 08 On-Time Delivery ## Quality You Can Count On Request a Quote → --- # Request a Quote | H&L Manufacturing URL: https://hlmanufacturing.com/request-quote Description: Submit your project specs for a competitive quote. Wire harness, overmolding, control panel, or assembly services from H&L Manufacturing. RFQ # Request a Quote Tell us about your project and we'll get back to you as soon as possible. - 01 Your Information - 02 Project Details - 03 Upload Files - 04 Review & Submit Full Name * Company Name * Email * Phone Job Title / Role Next → --- # Resources & Technical Guides | H&L Manufacturing URL: https://hlmanufacturing.com/resources Description: Technical articles, guides, and best practices for wire harness engineers and procurement teams from H&L Manufacturing. Knowledge Base # Resources & Technical Guides Technical articles, guides, and best practices for engineers and procurement teams. All Wire Harness Basics Industry Guide Materials Guide Wire Harness Basics ## What Is a Wire Harness? Complete Manufacturing Guide Everything you need to know about wire harnesses — what they are, how they're made, and why they matter. 8 min read Read More → Wire Harness Basics ## Wire Harness vs. Cable Assembly: What's the Difference? Understand the key differences between wire harnesses and cable assemblies and when to use each. 5 min read Read More → Industry Guide ## How to Choose a Wire Harness Manufacturer Key factors to consider when selecting a contract manufacturer for your wire harness needs. 7 min read Read More → Materials Guide ## What Is Overmolding? Process, Materials & Applications A comprehensive guide to the overmolding process, material options, and common applications. 6 min read Read More → Wire Harness Basics ## Wire Gauge Selection Guide: AWG Chart & Best Practices How to select the right wire gauge for your application with our AWG chart and selection tips. 6 min read Read More → Industry Guide ## Understanding IPC/WHMA-A-620 Standards What the IPC/WHMA-A-620 standard means for wire harness quality and workmanship. 5 min read Read More → Materials Guide ## Connector Selection Guide: Molex, TE, Deutsch & JST Compare major connector brands and choose the right one for your wire harness application. 8 min read Read More → Wire Harness Basics ## Wire Harness Design Best Practices for Engineers Design tips and best practices to optimize your wire harness for manufacturability and reliability. 10 min read Read More → --- # Connector Selection Guide: Molex, TE, Deutsch & JST | H&L Manufacturing URL: https://hlmanufacturing.com/resources/connector-selection-guide Description: Compare major connector brands — Molex, TE Connectivity, Deutsch, JST, Amphenol — and choose the right one for your wire harness application. Resources / Materials Guide # Connector Selection Guide: Molex, TE, Deutsch & JST 8 min read · Materials Guide The connector is where the wire harness meets the real world. It's the point where power and signals transfer between your harness and the components it serves — and it's also the most common point of failure if the wrong connector is specified. Choosing the right connector family for each connection point is critical to harness reliability, cost, and serviceability. This guide covers the four most widely used connector brands in wire harness manufacturing — Molex, TE Connectivity, Deutsch, and JST — along with Amphenol and the key factors that drive connector selection. ## Key Selection Factors Before comparing brands, understand the factors that narrow your options: - Current rating — how much current does each circuit carry? This determines the contact size and connector series. - Pin count — how many circuits does the connector need to carry? Connectors range from single-pin to 100+ positions. - Environment — will the connector be exposed to water, dust, chemicals, vibration, or extreme temperatures? This determines whether you need a sealed or unsealed connector. - Mating cycles — how often will the connector be plugged and unplugged? Field-serviceable connections need higher cycle ratings. - Wire gauge range — the connector and its terminals must accommodate the wire gauges in your design. - Space constraints — connector size and profile matter, especially in dense assemblies and tight enclosures. - Cost — sealed, high-performance connectors cost significantly more than basic unsealed housings. Specify what you need, not more. ## Molex Molex is one of the largest connector manufacturers in the world, offering an enormous range of connector families for virtually every application. Popular series for wire harness applications: - Micro-Fit 3.0 — compact power connector, 3.0mm pitch, up to 5A per circuit. Ideal for internal power connections to PCBs and control modules. - Mini-Fit Jr. — workhorse power connector, 4.2mm pitch, up to 13A per circuit. One of the most widely used connectors in industrial and commercial harnesses. - MX150 — sealed automotive connector, IP67/IP69K rated, designed for under-hood and exterior vehicle applications. - KK 254 — 2.54mm pitch signal connector for low-current PCB interfaces. Best for: internal power and signal connections, PCB interfaces, consumer and industrial products. ## TE Connectivity TE Connectivity (formerly Tyco/AMP) offers a massive portfolio spanning automotive, industrial, aerospace, and consumer markets. TE connectors are widely specified in OEM automotive harnesses. Popular series for wire harness applications: - MATE-N-LOK — robust power connector, available in multiple sizes and configurations, up to 17A. Common in industrial and appliance harnesses. - AMP Superseal 1.5 — sealed automotive connector, IP67, designed for harsh automotive and off-highway environments. - MCP / MCON — compact automotive connectors widely used in European automotive platforms. - Universal MATE-N-LOK — versatile industrial connector with blade and receptacle contacts. Best for: automotive OEM harnesses, industrial power distribution, sealed connections. ## Deutsch Deutsch (now part of TE Connectivity) connectors are the go-to choice for harsh-environment, sealed applications. They're built like tanks — heavy-duty housings, robust locking mechanisms, and environmental sealing that handles the worst conditions. Popular series for wire harness applications: - DT Series — the most widely used Deutsch connector. Environmentally sealed, thermoplastic housing, 13A rated. The standard for agricultural, construction, and truck harnesses. - DTM Series — smaller pin size version of the DT, for lower-current signal applications in sealed environments. - HD Series — heavy-duty, high-pin-count sealed connectors for complex harnesses in severe environments. - DTP Series — high-current version (25A rated) for power distribution in heavy equipment. Best for: agriculture, heavy equipment, trucks, off-highway, marine — any sealed, high-vibration application. ## JST JST (Japan Solderless Terminals) specializes in compact, cost-effective connectors primarily for signal-level and low-power applications. JST connectors are extremely popular in consumer electronics, LED lighting, and low-current control wiring. Popular series for wire harness applications: - XH Series — 2.5mm pitch, crimp-style, up to 3A. Very common in consumer products and PCB interconnects. - PH Series — 2.0mm pitch, compact signal connector for space-constrained designs. - SM Series — wire-to-wire connector, 2.5mm pitch, popular for LED and sensor connections. - VH Series — 3.96mm pitch, higher current capacity, used in power supply and appliance applications. Best for: signal connections, LED wiring, consumer electronics, cost-sensitive low-current applications. ## Amphenol Amphenol is a major connector manufacturer with particular strength in mil-spec, aerospace, and high-reliability industrial connectors. Their circular connectors are widely used in applications requiring extreme durability. - Amphe-Lite — lightweight circular connectors for aerospace and defense. - AT Series — environmentally sealed automotive/industrial connectors, similar to Deutsch DT in application. - Industrial circular connectors — heavy-duty, multi-pin connectors for factory automation and machinery. Best for: aerospace, defense, industrial automation, high-reliability applications. ## Quick Comparison Brand Strength Typical Use Sealed Options Molex Broad range, PCB interfaces Industrial, consumer, automotive Yes (MX150, etc.) TE Connectivity Automotive OEM depth Automotive, industrial, appliance Yes (Superseal, etc.) Deutsch Harsh environment durability Ag, heavy equipment, trucks All series sealed JST Compact, cost-effective Signal, LED, consumer electronics Limited Amphenol High-reliability, mil-spec Aerospace, defense, industrial Yes (most series) ## The Bottom Line There's no single "best" connector — only the best connector for your specific application. Match the connector to the environment, current, pin count, and serviceability requirements of each connection point. Don't over-specify (sealed connectors where unsealed will do), and don't under-specify (cheap connectors in harsh environments). When in doubt, work with your wire harness manufacturer — they've seen thousands of applications and know what works. H&L Connector Expertise H&L Manufacturing works with Molex, TE Connectivity, Deutsch, JST, Amphenol, and custom connectors across all our wire harness programs. We support crimp, solder, IDC, and ultrasonic weld terminations — with crimp force monitoring and cross-section analysis to verify every connection. Send us your BOM and we'll help you select the right connectors for your application. ## Connector Selection FAQ Common questions about choosing connectors for wire harness applications. ### How do I know which connector brand to use? Start with the application requirements: current rating, pin count, sealing, mating cycles, and environment. If your customer's spec calls out a specific connector, use that. If you have flexibility, your manufacturer can recommend the best option based on experience with similar applications. H&L works with Molex, TE Connectivity, Deutsch, JST, Amphenol, and custom connectors. ### What's the difference between sealed and unsealed connectors? Sealed connectors use gaskets, interfacial seals, or cavity plugs to prevent moisture and contaminants from entering the connector housing. They're rated by IP (Ingress Protection) codes — IP67 and IP69K being common for harsh environments. Unsealed connectors are lighter and cheaper but only suitable for dry, protected environments. ### Can I mix connector brands in the same harness? Yes — it's very common. A single wire harness might use Deutsch connectors for sealed engine-bay connections, Molex Micro-Fit for internal control board interfaces, and JST for low-current signal connections. The key is matching the right connector to each connection point's requirements. ### What does 'mating cycles' mean? Mating cycles refers to the number of times a connector can be plugged in and unplugged while maintaining reliable electrical contact. A connector rated for 25 mating cycles is designed for permanent or semi-permanent installation. One rated for 10,000+ cycles is designed for frequent connect/disconnect, like test equipment or field service connections. ### Does H&L stock connectors or do I need to supply them? H&L can source connectors and components on your behalf based on your BOM, or we can work with customer-supplied materials. We have established relationships with major connector distributors and can often leverage volume pricing. ### What if my application needs a custom connector? H&L supports custom connector solutions including overmolded terminations, custom pin configurations, and application-specific housings. Our engineering team can help design a solution that meets your exact requirements when off-the-shelf connectors don't fit. ### How do I specify connectors on my wire harness drawing? Include the manufacturer name, part number, and mating part number for each connector. Specify the terminal/contact part numbers, wire gauge for each cavity, and any sealing components (cavity plugs, interfacial seals). The more detail on your drawing or BOM, the more accurate your quote and first-article build will be. ### What connector termination methods does H&L support? H&L supports crimp, solder, IDC (insulation displacement), and ultrasonic weld terminations. Crimp is the most common method for wire harness connectors. We use calibrated crimp tooling with crimp force monitoring to ensure every termination meets spec. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # How to Choose a Wire Harness Manufacturer | H&L Manufacturing URL: https://hlmanufacturing.com/resources/how-to-choose-manufacturer Description: Key factors to consider when selecting a contract manufacturer for your wire harness needs — quality, capabilities, and what to look for. Resources / Industry Guide # How to Choose a Wire Harness Manufacturer 7 min read · Industry Guide Choosing a wire harness manufacturer is one of the most consequential decisions an OEM makes. Your wire harness partner directly impacts product quality, lead times, cost structure, and — ultimately — your reputation with your own customers. The wrong choice can mean missed deliveries, field failures, and expensive re-work. The right choice gives you a reliable supply chain partner for years. Here's what to evaluate when selecting a wire harness manufacturer — and what sets the best apart from the rest. ## 1. Quality Systems & Certifications Quality isn't optional in wire harness manufacturing — a single bad crimp or miswired circuit can cause a field failure, a safety recall, or a line shutdown at your plant. Look for manufacturers that hold: - ISO 9001:2015 certification — confirms a documented, audited quality management system is in place. - IPC/WHMA-A-620 compliance — the industry standard for wire harness and cable assembly workmanship. - UL approval — required for products that need to meet UL safety standards. - 100% electrical testing — every harness should be tested for continuity and shorts before it ships. No sampling. Every unit. H&L Manufacturing is ISO 9001:2015 certified, UL Approved, builds to IPC/WHMA-A-620 standards, and electrically tests every harness. ## 2. Vertical Integration The best wire harness manufacturers don't just cut, crimp, and assemble. They offer a full range of capabilities under one roof — eliminating the need to coordinate between multiple vendors and reducing your total lead time. Ask whether your potential manufacturer can handle: - Wire cutting, stripping, and crimping - Harness assembly and board builds - Overmolding for sealed connectors - Control panel wiring and assembly - General assembly and box builds - Prototyping and 3D printing for fixtures and jigs H&L offers all of the above from a single 54,000+ sq ft facility in Middleville, Michigan. One vendor, one point of contact, zero handoff delays. ## 3. Prototype-to-Production Scalability Many manufacturers specialize in either low-volume prototypes or high-volume production — but not both. This forces OEMs to switch vendors as their program scales, which introduces risk, delays, and re-qualification costs. The ideal partner can build 5 prototype units for your engineering team, refine the design based on feedback, and then ramp to thousands of units per month — all without changing vendors. H&L supports everything from single prototype builds to high-volume production. You never need to switch vendors as your program grows. ## 4. Domestic Manufacturing Offshore manufacturing can look attractive on a per-piece cost basis, but the total cost often tells a different story. When you factor in shipping, customs, inventory carrying costs, communication challenges, quality inconsistency, and the risk of IP exposure, domestic manufacturing frequently wins on total value. A U.S.-based manufacturer gives you: - Shorter, more predictable lead times - Real-time communication in your time zone - Stronger intellectual property protection - Lower shipping costs and smaller inventory requirements - The ability to visit the facility and audit processes in person ## 5. Engineering Support A great wire harness manufacturer doesn't just build what you design — they make it better. Look for a partner that offers design-for-manufacturability (DFM) feedback, material and connector recommendations, and the ability to catch potential issues before they become production problems. Engineering support is especially valuable during the prototype phase, where small design changes can significantly impact cost, reliability, and assembly time at volume. ## 6. Track Record & Industry Experience Experience matters. A manufacturer that has served your industry understands the specific requirements, connector families, environmental challenges, and compliance standards your product demands. Ask for references, case studies, and examples of similar work. H&L has been manufacturing wire harnesses for over 59 years, serving automotive, agriculture, industrial controls, consumer products, RV, and utility trailer OEMs. We've earned customer excellence awards from Webasto and Alpine Electronics. ## 7. Communication & Responsiveness Pay attention to how a manufacturer communicates during the quoting process — it's a preview of how they'll communicate during production. Are they responsive? Do they ask smart questions about your application? Do they proactively flag potential issues? A manufacturer that's engaged and curious during the quote process will be a better partner over the life of the program. ## The Bottom Line The cheapest quote isn't always the best value. When evaluating wire harness manufacturers, look beyond piece price and consider quality systems, vertical integration, scalability, location, engineering support, and track record. The right partner pays for itself through fewer quality issues, shorter lead times, and a smoother production ramp. Why H&L Manufacturing 59+ years in business. ISO 9001:2015 certified. UL Approved. Vertically integrated with wire harness, overmolding, control panel, general assembly, and 3D printing capabilities. 100% electrical testing. American-made in Middleville, Michigan. Customer excellence awards from Webasto and Alpine Electronics. Send us your specs and see the difference. ## Choosing a Manufacturer FAQ Common questions about selecting the right wire harness manufacturing partner. ### What certifications should a wire harness manufacturer have? At minimum, look for ISO 9001:2015 certification (quality management system) and adherence to IPC/WHMA-A-620 workmanship standards. UL approval is important if your product requires UL-listed components. H&L Manufacturing holds ISO 9001:2015 certification and is UL Approved. ### Should I choose a domestic or offshore manufacturer? Domestic manufacturing offers shorter lead times, easier communication, no language barriers, stronger IP protection, and lower shipping costs. Offshore can offer lower piece prices but often comes with longer lead times, quality variability, and hidden logistics costs. For most OEMs, a U.S.-based manufacturer provides better total value. ### How important is vertical integration? Very. A vertically integrated manufacturer handles cutting, crimping, assembly, overmolding, testing, and packaging under one roof. This reduces lead times, eliminates vendor coordination, and gives you a single point of accountability. H&L offers wire harness, overmolding, control panel, general assembly, and 3D printing — all in one facility. ### What if I only need a small quantity or a prototype? Many large manufacturers have high minimum order quantities. Look for a partner that supports prototype-to-production — someone who can build 5 pieces for validation and then scale to 5,000 without switching vendors. H&L supports everything from single prototypes to high-volume production runs. ### How do I evaluate a manufacturer's quality process? Ask about their testing procedures (do they electrically test every harness?), inspection standards (IPC/WHMA-A-620 compliance), and traceability systems. Request a facility tour if possible. H&L electrically tests 100% of harnesses and inspects every assembly before shipment. ### What information should I provide when requesting a quote? Provide a wiring schematic or drawing, bill of materials (BOM), connector and terminal specifications, wire gauges and lengths, and expected annual volumes. The more detail you provide upfront, the more accurate your quote will be. ### How do I know if a manufacturer can handle my industry's requirements? Ask about their experience in your specific industry. A manufacturer serving automotive, agriculture, industrial controls, and recreational vehicles will have different capabilities than one focused solely on consumer electronics. H&L serves automotive, ag, industrial, RV, utility trailer, and consumer product OEMs. ### What makes H&L Manufacturing different from other wire harness manufacturers? H&L combines 59+ years of experience, ISO 9001:2015 certification, UL approval, vertical integration (wire harness, overmolding, control panels, assembly, 3D printing), 100% electrical testing, and domestic manufacturing in Middleville, Michigan. We've earned customer excellence awards from partners like Webasto and Alpine Electronics. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Understanding IPC/WHMA-A-620 Standards | H&L Manufacturing URL: https://hlmanufacturing.com/resources/ipc-whma-a-620-standards Description: What the IPC/WHMA-A-620 standard means for wire harness quality, workmanship requirements, and inspection criteria. Resources / Industry Guide # Understanding IPC/WHMA-A-620 Standards 5 min read · Industry Guide IPC/WHMA-A-620 is the only industry-consensus standard that defines the requirements and acceptance criteria for cable and wire harness assemblies. Jointly developed by IPC (Association Connecting Electronics Industries) and WHMA (Wire Harness Manufacturer's Association), it serves as the universal reference for what constitutes acceptable workmanship in wire harness manufacturing. If you're an engineer specifying a wire harness, a procurement professional qualifying a supplier, or a manufacturer building assemblies — this standard is the common language you share. Here's what it covers and why it matters. ## What the Standard Covers IPC/WHMA-A-620 provides detailed visual and dimensional criteria for evaluating wire harness workmanship. It defines three conditions for each inspection area: - Target — the ideal, preferred condition. - Acceptable — meets the requirements for the specified product class. - Defect — does not meet the requirements and must be reworked or rejected. The standard covers virtually every aspect of wire harness construction: - Crimp terminations — crimp height, bellmouth, insulation support, conductor brush, and pull-force requirements. - Solder terminations — solder flow, wetting, fill, and acceptable joint profiles. - Insulation displacement connections (IDC) — conductor seating, insulation clearance. - Ultrasonic welds — weld quality and integrity criteria. - Wire routing and bundling — bend radius, wire crossings, tie placement, and lacing. - Connector and terminal insertion — proper seating, retention, and pin alignment. - Sleeving and protective coverings — heat shrink, braided loom, corrugated tubing, and tape application. - Labeling and marking — legibility, placement, and durability. - Molding and potting — overmold quality, voids, and flash. - Coaxial and fiber optic assemblies — specialized criteria for RF and optical connections. ## The Three Product Classes One of the most important concepts in IPC/WHMA-A-620 is the class system . The standard defines three classes, each with progressively stricter acceptance criteria: Class Name Description Examples Class 1 General Electronic Products Function is the primary requirement. Cosmetic imperfections are more tolerable. Consumer electronics, disposable products Class 2 Dedicated Service Products Extended life and reliable, uninterrupted performance required. The most commonly specified class. Industrial equipment, automotive, agricultural machinery, commercial products Class 3 High-Reliability Products Continued performance is critical. Equipment downtime is unacceptable. Strictest criteria. Life-support, military, aerospace, critical infrastructure The class determines how strictly each workmanship criterion is judged. A condition that's acceptable in Class 1 might be a defect in Class 3. Most industrial, automotive, and commercial wire harnesses are built to Class 2 . ## Why IPC/WHMA-A-620 Matters ### Common Language Without a shared standard, "good quality" is subjective. A-620 gives manufacturers, inspectors, and customers a common reference point — eliminating ambiguity about what's acceptable and what's not. ### Consistent Quality Manufacturers that train their assemblers and inspectors to A-620 produce more consistent results. The standard provides clear visual examples of target, acceptable, and defect conditions that operators can reference on the production floor. ### Supplier Qualification OEMs use A-620 compliance as a baseline for qualifying wire harness suppliers. A manufacturer that doesn't follow A-620 may not be able to compete for contracts in automotive, industrial, or defense markets. ### Risk Reduction Wire harness failures in the field are expensive — warranty claims, line shutdowns, safety recalls, and damaged customer relationships. Building to A-620 standards significantly reduces these risks by catching workmanship issues before they leave the factory. ## Key Inspection Areas While the standard covers dozens of inspection points, these are the areas that most frequently determine pass/fail: - Crimp quality — the single most critical area. A bad crimp is the #1 cause of wire harness failure. The standard defines acceptable crimp height, bellmouth, insulation grip, and conductor visibility. - Wire damage — nicks, cuts, or broken strands in the conductor that weaken the wire and can cause intermittent failures. - Connector pin seating — terminals must be fully inserted and properly retained in the connector housing. Partially seated pins can back out under vibration. - Strain relief — proper support at cable-to-connector junctions prevents wire fatigue and pullout. - Wire routing — proper bend radii, no pinch points, adequate clearance from heat sources and moving parts. ## How H&L Applies the Standard At H&L Manufacturing, IPC/WHMA-A-620 isn't just a document on a shelf — it's built into our daily production process: - Assemblers are trained to A-620 workmanship criteria - Every harness undergoes visual inspection per A-620 before electrical testing - 100% end-of-line continuity and short-circuit testing with integrated vision systems - Crimp force monitoring validates every crimped termination in real time - Cross-section analysis verifies crimp geometry on a sampling basis - ISO 9001:2015 quality management system provides the framework for continuous improvement Quality You Can Trust H&L Manufacturing is ISO 9001:2015 certified, UL Approved, and builds every wire harness to IPC/WHMA-A-620 workmanship standards. With 59+ years of experience and customer excellence awards from Webasto and Alpine Electronics, we deliver the quality and reliability your product demands. ## IPC/WHMA-A-620 FAQ Common questions about the IPC/WHMA-A-620 wire harness workmanship standard. ### Is IPC/WHMA-A-620 certification mandatory? It's not legally mandatory in most cases, but many OEMs and industries require it as a contract condition. In practice, it has become the baseline expectation for any reputable wire harness manufacturer. If your manufacturer doesn't follow A-620, that's a red flag. ### What is the difference between Class 1, Class 2, and Class 3? Class 1 is for general-use products where function is the primary requirement. Class 2 is for dedicated-service products where extended life and reliable performance are expected — this is the most common class for industrial and automotive harnesses. Class 3 is for high-reliability products where failure is not acceptable, such as life-support, military, and aerospace applications. ### What version of the standard is current? The current version is IPC/WHMA-A-620E, released in 2024. It supersedes revision D (2020) and includes updated requirements and clarifications. Manufacturers should be building to the latest revision unless a customer specification calls out a specific version. ### Does the standard cover crimping? Yes — extensively. IPC/WHMA-A-620 defines acceptable and defect conditions for crimp terminations, including crimp height, bellmouth, insulation support, conductor visibility, and wire brush. Crimp quality is one of the most critical areas the standard addresses. ### Does H&L build to IPC/WHMA-A-620 standards? Yes. H&L Manufacturing follows IPC/WHMA-A-620 workmanship standards across all wire harness production. Every harness is visually inspected and 100% electrically tested. We also perform crimp force monitoring and cross-section analysis to verify termination quality. ### What's the difference between IPC/WHMA-A-620 and IPC-A-610? IPC-A-610 covers the acceptability of electronic assemblies (PCBs), while IPC/WHMA-A-620 specifically covers cable and wire harness assemblies. They're companion standards — a product that includes both a PCB and a wire harness would reference both. ### Can I request a specific class for my wire harness? Absolutely. The product class should be defined in your specification or purchase order. If no class is specified, Class 2 is typically assumed. If your application requires Class 3, discuss this with your manufacturer upfront — it affects inspection criteria, documentation, and cost. ### How does IPC/WHMA-A-620 relate to ISO 9001? They're complementary. ISO 9001 defines the quality management system — the processes, documentation, and continuous improvement framework. IPC/WHMA-A-620 defines the specific workmanship criteria for wire harness assemblies. A manufacturer should ideally have both: ISO 9001 for the system and A-620 for the product standard. H&L is ISO 9001:2015 certified and builds to A-620. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # What Is a Wire Harness? Complete Manufacturing Guide | H&L Manufacturing URL: https://hlmanufacturing.com/resources/what-is-a-wire-harness Description: Everything you need to know about wire harnesses — what they are, how they're made, and why they matter in manufacturing. Resources / Wire Harness Basics # What Is a Wire Harness? Complete Manufacturing Guide 8 min read · Wire Harness Basics A wire harness — also called a wiring harness, cable harness, or wiring loom — is an organized assembly of wires, cables, connectors, and terminals that transmits electrical power and signals throughout a device or system. Think of it as the electrical nervous system of a machine: it routes power and data from point A to point B, keeps everything organized, and protects the wiring from damage. From the dashboard of your car to the control systems in an industrial plant, wire harnesses are everywhere. They're one of the most critical — and most overlooked — components in modern manufacturing. ## Why Wire Harnesses Exist Without a wire harness, each wire in a system would need to be individually routed, connected, and secured. In a car alone, that could mean hundreds of individual wires running loose through the vehicle. A wire harness solves this by bundling those wires into a single, structured assembly that's designed to fit a specific application. This approach offers several advantages: - Faster installation — one harness replaces dozens of individual wires, reducing assembly time dramatically. - Improved reliability — standardized connections reduce the risk of wiring errors and intermittent faults. - Space optimization — bundled wires take up less room and can be routed through tight spaces. - Protection — sleeves, looms, and conduit shield wires from abrasion, heat, moisture, and vibration. - Easier troubleshooting — organized wiring is far easier to inspect, test, and repair. ## Key Components of a Wire Harness Every wire harness is unique to its application, but most share a common set of components: - Wires & cables — the conductors that carry electrical current. Wire gauge (AWG) is selected based on the current load, voltage drop, and operating environment. - Connectors — standardized housings (Molex, TE Connectivity, Deutsch, JST, etc.) that allow the harness to mate with components. Connector choice depends on pin count, current rating, sealing requirements, and mating cycles. - Terminals & contacts — crimped or soldered onto wire ends to make electrical connections inside the connectors. - Protective sleeving — braided loom, split tubing, heat shrink, or corrugated conduit that shields wires from abrasion, heat, chemicals, and UV exposure. - Fasteners & mounting hardware — cable ties, P-clamps, adhesive mounts, and grommets that secure the harness to the structure. - Labels & markings — identification tags, wire markers, and shrink labels for traceability and field service. ## How Wire Harnesses Are Manufactured Wire harness manufacturing is a multi-step process that combines precision engineering with hands-on craftsmanship. Here's how it works at a high level: ### 1. Engineering & Design Review The process starts with a wiring schematic or drawing provided by the customer. Engineers review the design for manufacturability, verify component specifications, and identify potential issues before production begins. This step often includes collaboration between the manufacturer and the customer's engineering team. ### 2. Wire Cutting & Preparation Wires are cut to specified lengths and stripped to expose the conductor. For higher-volume production, automated cut-and-strip machines handle this with precision. Wires may also be marked or labeled at this stage for identification during assembly. ### 3. Crimping & Termination Terminals and contacts are crimped onto the stripped wire ends using calibrated crimp tools or automated crimp presses. Crimp quality is critical — a bad crimp is one of the leading causes of harness failure. Pull-force testing and cross-section analysis are used to verify crimp integrity. ### 4. Assembly on Harness Board Terminated wires are routed on a harness assembly board (also called a jig or fixture) that mirrors the harness's final shape and routing path. Assemblers insert terminals into connectors, apply protective sleeving, bundle wires with ties or tape, and attach mounting hardware — all according to the assembly drawing. ### 5. Electrical Testing Every completed harness is electrically tested for continuity (are all circuits complete?), shorts (are any wires touching that shouldn't be?), and in some cases, hi-pot or insulation resistance. Automated test fixtures can verify hundreds of circuits in seconds. ### 6. Final Inspection & Packaging After passing electrical testing, harnesses undergo a visual inspection for workmanship quality — checking crimp integrity, wire routing, connector seating, label placement, and overall build quality against IPC/WHMA-A-620 standards. Approved harnesses are packaged and shipped to the customer. ## Common Applications Wire harnesses are found in nearly every product that uses electricity. Some of the most common applications include: - Automotive — engine harnesses, body wiring, lighting, infotainment, and sensor systems. - Agriculture & heavy equipment — tractor controls, implement wiring, and cab harnesses. - Industrial automation — control panel wiring, sensor cables, and PLC interconnects. - Consumer & commercial products — appliances, HVAC systems, vending machines, and fitness equipment. - Recreational vehicles — RV electrical systems, boat wiring, and powersport harnesses. - Utility trailers — lighting, braking, and accessory circuits. ## What to Look for in a Wire Harness Manufacturer Not all wire harness manufacturers are created equal. When evaluating a potential partner, consider: - Vertically integrated capabilities — can they handle everything from cutting and crimping to overmolding and final assembly under one roof? - Quality standards — do they follow IPC/WHMA-A-620? Do they electrically test every harness? - Prototype-to-production scalability — can you start with a few pieces and scale to thousands without switching vendors? - Domestic manufacturing — U.S.-based production means shorter lead times, easier communication, and full IP protection. - Engineering support — a good manufacturer doesn't just build your design. They improve it. About H&L Manufacturing H&L Manufacturing has been building custom wire harnesses in Middleville, Michigan for over 59 years. We offer wire harness manufacturing, overmolding, control panel assembly, general assembly, and rapid prototyping — all under one roof. Every harness is electrically tested and built to IPC/WHMA-A-620 standards. ## Wire Harness FAQ Common questions about wire harnesses, manufacturing, and working with H&L. ### What is the difference between a wire harness and a cable assembly? A wire harness organizes individual wires and cables into a structured bundle using ties, clamps, and lacing, while a cable assembly encases multiple conductors inside a single outer jacket or sheath. Wire harnesses are typically used for internal routing; cable assemblies are designed for external or harsher environments where added protection is needed. ### How long does it take to manufacture a custom wire harness? Lead times depend on complexity, volume, and component availability. Simple prototypes can be built in a matter of days, while production runs are scheduled based on your delivery requirements. At H&L, we work closely with customers to meet tight deadlines without sacrificing quality. ### What industries use wire harnesses? Wire harnesses are used in virtually every industry that relies on electrical systems — including automotive, agriculture, heavy equipment, industrial automation, consumer products, recreational vehicles, utility trailers, medical devices, and aerospace. ### What quality standards apply to wire harness manufacturing? The primary standard is IPC/WHMA-A-620, which defines workmanship requirements for cable and wire harness assemblies. This covers crimping, soldering, wire routing, and overall assembly quality. H&L follows IPC/WHMA-A-620 and electrically tests every harness before shipment. ### Can I get a prototype before committing to a full production run? Absolutely. Prototyping is a smart step before committing to production tooling and volumes. H&L offers rapid prototype builds with engineering feedback so you can validate fit, form, and function before scaling up. ### What information do I need to provide for a wire harness quote? Ideally, you'd provide a wiring diagram or schematic, a bill of materials (BOM), connector and terminal specifications, wire gauges and lengths, and your expected annual volume. Even if you only have a rough sketch, our engineering team can help refine the design. ### What wire gauges can be used in a harness? Wire gauges typically range from 28 AWG (very fine signal wire) to 4/0 AWG (heavy power cable). The gauge you need depends on the current load, voltage, distance, and environmental conditions of your application. Most industrial harnesses use wire in the 10–22 AWG range. ### What causes wire harness failures? Common failure causes include poor crimp connections, inadequate strain relief, chafing from vibration, exposure to heat or chemicals, incorrect wire gauge selection, and lack of proper testing during manufacturing. Working with an experienced manufacturer significantly reduces these risks. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # What Is Overmolding? Process, Materials & Applications | H&L Manufacturing URL: https://hlmanufacturing.com/resources/what-is-overmolding Description: A comprehensive guide to the overmolding process, material options, and common applications for connectors and cable assemblies. Resources / Materials Guide # What Is Overmolding? Process, Materials & Applications 6 min read · Materials Guide Overmolding is a manufacturing process in which a second material — typically a thermoplastic or elastomer — is molded directly over an existing component to create a single, integrated part. In wire harness manufacturing, overmolding is most commonly used to seal and reinforce the connection point between a cable and its connector, creating a durable, waterproof, strain-relieved termination. If you've ever seen a power cord with a smooth rubber grip molded around the plug, you've seen overmolding in action. In industrial and automotive applications, the stakes are higher — overmolded connectors protect critical electrical connections in environments where moisture, vibration, chemicals, and extreme temperatures would destroy a standard connector. ## How the Overmolding Process Works The overmolding process for wire harness connectors follows a series of precise steps: ### 1. Harness Assembly The wire harness is built first — wires are cut, stripped, terminated, and inserted into connectors following the assembly drawing. The completed sub-assembly is then prepared for the overmolding step. ### 2. Tooling Setup Custom-designed mold tooling is loaded into the molding press. The tooling is specific to the connector shape, cable diameter, and desired overmold geometry. Proper tooling design is critical — it determines the seal integrity, strain relief profile, and overall appearance of the finished part. ### 3. Part Placement The assembled connector and cable are placed into the mold cavity and secured. Precise positioning ensures the overmold material flows evenly around the connector body and cable jacket. ### 4. Injection Heated thermoplastic material is injected into the mold under controlled pressure. The material flows around the connector and cable, bonding to the surfaces and filling the mold cavity. Temperature, pressure, and injection speed are carefully controlled to ensure a complete fill without damaging the wire or connector. ### 5. Cooling & Ejection The mold is cooled, the material solidifies, and the finished part is ejected. The result is a seamless, one-piece termination that integrates the connector, cable, and protective overmold into a single assembly. ### 6. Inspection & Testing Every overmolded assembly is visually inspected for defects (flash, voids, incomplete fill) and electrically tested to verify that the molding process didn't damage any circuits. ## Common Overmolding Materials Material selection depends on the operating environment and performance requirements: - TPE (Thermoplastic Elastomer) — flexible, good chemical resistance, wide temperature range. The most common choice for general-purpose overmolding. - TPU (Thermoplastic Polyurethane) — excellent abrasion resistance, high flexibility, strong bonding. Ideal for applications with mechanical wear. - PVC (Polyvinyl Chloride) — cost-effective, good electrical insulation, moderate flexibility. Widely used in consumer and commercial products. - Nylon (Polyamide) — rigid, high heat resistance, excellent chemical resistance. Used where structural strength is needed at the connector. ## Benefits of Overmolding - Environmental sealing — creates a watertight barrier against moisture, dust, oil, and chemicals. - Strain relief — reinforces the cable-to-connector junction, preventing wire fatigue and pullout failures. - Vibration resistance — a solid overmold absorbs vibration and prevents connector loosening in mobile equipment. - Reduced assembly steps — eliminates the need for separate boots, heat shrink, grommets, or potting compounds. - Professional appearance — clean, consistent look with custom color and branding options. - Improved reliability — fewer potential failure points compared to multi-component sealing methods. ## Common Applications Overmolded connectors and assemblies are used across a wide range of industries: - Automotive — engine bay harnesses, sensor connections, lighting, and under-body wiring exposed to water, salt, and heat. - Agriculture & heavy equipment — implement harnesses, cab controls, and hydraulic sensor connections that face mud, moisture, and vibration daily. - Industrial controls — factory floor sensor cables, actuator connections, and control panel interfaces in washdown environments. - Marine & outdoor — boat wiring, outdoor power equipment, and any application with constant water or UV exposure. - Consumer products — power tool cords, appliance connections, and exercise equipment where durability and safety are priorities. ## Overmolding vs. Other Sealing Methods Overmolding isn't the only way to protect a connector, but it's often the best. Here's how it compares: Method Seal Quality Strain Relief Durability Overmolding Excellent Excellent Highest Heat shrink boots Good Moderate Moderate Potting compound Good Good Good (not reworkable) Rubber boots / grommets Fair Fair Lower ## The Bottom Line Overmolding transforms a vulnerable connection point into a sealed, strain-relieved, production-ready termination. It costs more than a basic connector — but it pays for itself by eliminating field failures, reducing assembly steps, and extending the life of the harness in demanding environments. If your connectors are exposed to anything worse than a climate-controlled office, overmolding deserves serious consideration. H&L Overmolding Capabilities H&L Manufacturing provides custom overmolding as part of our vertically integrated process. We design and build tooling in-house, select the right material for your application, and deliver overmolded wire harness assemblies — from prototype through production — all from our facility in Middleville, Michigan. ## Overmolding FAQ Common questions about the overmolding process and applications. ### What is the difference between overmolding and insert molding? Overmolding applies a second material over an existing part or substrate — such as molding rubber over a connector. Insert molding places a component (like a metal terminal) into a mold and injects plastic around it. Both are used in wire harness manufacturing; the right choice depends on your application. ### What materials are used for overmolding? Common overmolding materials include TPE (thermoplastic elastomer), TPU (thermoplastic polyurethane), PVC, and nylon. Material selection depends on the operating environment — temperature range, chemical exposure, flexibility requirements, and UV resistance. ### How does overmolding improve connector reliability? Overmolding creates a sealed, monolithic bond between the cable and connector that eliminates entry points for moisture, dust, and contaminants. It also provides strain relief at the cable-to-connector junction, which is the most common failure point in wire harness assemblies. ### Can overmolding be added to an existing wire harness design? Yes. If your current harness uses standard connectors that are failing in the field due to moisture, vibration, or strain, overmolding can often be added to improve durability without a complete redesign. Our engineering team can evaluate your assembly and recommend the best approach. ### What industries benefit most from overmolded connections? Any industry where connectors are exposed to harsh conditions — automotive, agriculture, heavy equipment, marine, outdoor power equipment, industrial controls, and recreational vehicles. If your product operates outdoors or in wet, dusty, or high-vibration environments, overmolding is worth evaluating. ### Does H&L handle overmolding tooling in-house? Yes. H&L designs and builds custom overmolding tooling in-house, which gives us control over quality, lead times, and cost. We can also modify existing tooling as your design evolves. ### What is the typical lead time for overmolded assemblies? Lead times depend on tooling requirements and volume. If tooling already exists, production runs can start quickly. New tooling typically takes a few weeks to design and build. Contact us with your specs for a specific timeline. ### Is overmolding more expensive than using standard connectors? Overmolding adds cost per connector compared to a standard unsealed connection. However, it often reduces total cost of ownership by eliminating field failures, warranty claims, and the need for secondary sealing components like boots, heat shrink, or potting compounds. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Wire Gauge Selection Guide: AWG Chart & Best Practices | H&L Manufacturing URL: https://hlmanufacturing.com/resources/wire-gauge-selection-guide Description: How to select the right wire gauge for your application with our AWG chart, ampacity tables, and selection best practices. Resources / Wire Harness Basics # Wire Gauge Selection Guide: AWG Chart & Best Practices 6 min read · Wire Harness Basics Selecting the correct wire gauge is one of the most fundamental — and most consequential — decisions in wire harness design. Choose wire that's too thin and you risk overheating, voltage drop, and potential fire hazards. Choose wire that's too thick and you add unnecessary weight, cost, and difficulty to the harness assembly. This guide explains how the AWG system works, provides a reference chart, and covers the key factors that influence gauge selection. ## Understanding the AWG System The American Wire Gauge (AWG) system is the standard used in North America to specify wire size. The numbering system is inverse — smaller numbers mean thicker wire . A 10 AWG wire is significantly thicker and can carry much more current than a 22 AWG wire. As a rule of thumb, every decrease of 3 AWG sizes roughly doubles the cross-sectional area (and therefore the current capacity) of the wire. Every decrease of 6 AWG sizes roughly doubles the diameter. ## AWG Reference Chart The following chart shows common wire gauges used in wire harness manufacturing, along with their approximate diameter, cross-sectional area, and typical ampacity ratings for chassis wiring (copper, single conductor in free air at 30°C ambient). Actual ampacity depends on insulation type, bundling, ambient temperature, and installation conditions. AWG Diameter (in) Area (mm²) Ampacity* Typical Use 4/0 (0000) 0.460 107.2 230 A Heavy power feeds, battery cables 2 0.258 33.6 130 A Main power distribution 6 0.162 13.3 75 A Sub-panel feeds, large motors 10 0.102 5.26 40 A Power circuits, motor leads 12 0.081 3.31 30 A Branch circuits, lighting power 14 0.064 2.08 20 A General purpose, relays, solenoids 16 0.051 1.31 13 A Switches, indicators, small motors 18 0.040 0.82 10 A Control wiring, sensors, LED lighting 20 0.032 0.52 7 A Signal wiring, low-power electronics 22 0.025 0.33 5 A Data, communication, low-current signals 24 0.020 0.20 3.5 A Fine signal wire, instrumentation *Ampacity values are approximate for single copper conductor in free air at 30°C. Actual capacity varies with insulation rating, ambient temperature, and bundling. Always consult manufacturer specifications and applicable codes for your application. ## Key Factors in Wire Gauge Selection ### 1. Current Load The most important factor. The wire must be able to safely carry the maximum current the circuit will draw — including inrush current for motors and other inductive loads. Always size for peak current, not average operating current. ### 2. Voltage Drop Every wire has resistance, and resistance causes voltage drop — the longer the wire run, the greater the drop. In low-voltage systems (12V, 24V DC), voltage drop becomes critical much faster than in 120V or 240V AC systems. The general rule is to keep voltage drop under 3% at the load. For long runs, you'll often need to upsize the wire gauge beyond what ampacity alone would require. ### 3. Operating Temperature Higher ambient temperatures reduce the wire's current-carrying capacity because the insulation is already closer to its thermal limit. If your harness runs near engines, exhaust components, or industrial heat sources, you may need to upsize the wire or choose insulation rated for higher temperatures (XLPE, Teflon/PTFE, silicone). ### 4. Bundling & Conduit When multiple current-carrying wires are bundled together in a harness, each wire generates heat that affects its neighbors. Wire ampacity must be derated (reduced) based on the number of conductors in the bundle. A wire that can carry 20A by itself may only be rated for 14A when bundled with 10 other conductors. ### 5. Flexibility & Routing Thicker wire is stiffer and harder to route through tight spaces. In wire harness design, there's often a tradeoff between electrical capacity and physical flexibility. Stranded wire is almost always used in harnesses because it bends more easily than solid wire of the same gauge and resists fatigue from vibration. ### 6. Industry Standards & Specifications Many industries have specific wire gauge requirements. Automotive OEMs specify wire per SAE standards. Industrial control panels follow NEC and UL 508A requirements. Your customer's specification will often dictate wire type, gauge, and insulation — always check the spec before selecting wire. ## Common Wire Types in Harness Manufacturing - GPT / GXL / TXL — automotive-grade wire with thin-wall insulation. GXL and TXL are cross-linked for higher temperature resistance. Very common in vehicle and equipment harnesses. - MTW (Machine Tool Wire) — rated for use in industrial control panels and machine tools. Meets UL 1063 and is commonly specified for UL 508A panel builds. - THHN/THWN — building wire rated for both dry and wet locations. Used in some industrial harness and panel applications. - Teflon / PTFE — rated for extreme temperatures (up to 260°C). Used in aerospace, military, and high-heat industrial applications. - Silicone — flexible and high-temperature rated. Common in applications requiring extreme flexibility and heat resistance. ## Best Practices for Wire Gauge Selection - Size for peak current , not average operating current. Account for motor inrush, transient loads, and worst-case scenarios. - Calculate voltage drop for long runs, especially in low-voltage DC systems. Use the formula: V(drop) = I × R × 2 (round-trip distance). - Apply derating factors for bundled conductors and elevated ambient temperatures. - Use stranded wire in any application involving movement, vibration, or repeated flexing. - Match insulation to the environment — PVC for general use, cross-linked for under-hood, PTFE for extreme heat. - Follow the customer's specification — if the spec calls out a specific wire type and gauge, use it. If there's room for optimization, discuss it with the customer's engineering team. - Work with your manufacturer — an experienced harness manufacturer can catch gauge and insulation issues during design review, before they become production problems. H&L Wire Harness Capabilities H&L Manufacturing builds custom wire harnesses with a wide range of wire types and gauges. We support crimp, solder, IDC, and ultrasonic weld terminations across connector families including Molex, TE Connectivity, Deutsch, JST, and Amphenol. Every harness undergoes 100% end-of-line continuity and short testing with integrated vision systems. Our engineering team offers SolidWorks design assistance and APQP processes to help you get the wire selection right before production begins. ## Wire Gauge FAQ Common questions about wire gauge selection for harness applications. ### What does AWG stand for? AWG stands for American Wire Gauge. It's the standardized system used in North America to measure wire diameter. The numbering is counterintuitive — smaller AWG numbers mean thicker wire. For example, 10 AWG is much thicker than 22 AWG. ### What happens if I use wire that's too small for my application? Undersized wire creates excessive resistance, which generates heat. This can cause voltage drop at the load (leading to poor device performance), insulation breakdown, and in worst cases, melted wire or fire. Always size wire based on the maximum current the circuit will carry, not the average. ### What's the difference between stranded and solid wire? Solid wire is a single conductor — it's rigid and best suited for fixed, permanent installations. Stranded wire is made of multiple smaller conductors twisted together, making it flexible and resistant to fatigue from vibration and movement. Wire harnesses almost always use stranded wire because harnesses need to flex during installation and operation. ### How does wire length affect gauge selection? Longer wire runs have more resistance, which causes voltage drop. For long runs, you may need to upsize the wire gauge to keep voltage drop below acceptable limits — typically under 3% for most applications. This is especially important in 12V and 24V DC systems where the supply voltage is already low. ### What wire gauges does H&L typically work with? H&L manufactures wire harnesses using a wide range of wire gauges to suit each application. We work with everything from fine signal wire to heavier power conductors, and our team can help you select the right gauge based on your current, voltage, and environmental requirements. ### Does H&L test wire terminations for quality? Yes. H&L uses crimp force monitoring, cross-section analysis, and pull-force testing to verify crimp integrity. Every completed harness undergoes 100% continuity and short-circuit testing using automated end-of-line test fixtures with integrated vision systems. ### What insulation types are available for wire harness wire? Common insulation types include PVC (general purpose), cross-linked polyethylene (XLPE — higher temperature), Teflon/PTFE (extreme heat and chemical resistance), and TPE (flexible, halogen-free). The right insulation depends on your operating temperature, chemical exposure, and any industry-specific requirements. ### Can H&L help me select the right wire gauge for my design? Absolutely. H&L offers SolidWorks design assistance and APQP processes fitted to your needs. Our engineering team reviews every design for manufacturability and can recommend wire gauge, insulation type, and routing improvements before production begins. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Wire Harness Design Best Practices for Engineers | H&L Manufacturing URL: https://hlmanufacturing.com/resources/wire-harness-design-best-practices Description: Design tips and best practices to optimize your wire harness for manufacturability, reliability, and cost-effectiveness. Resources / Wire Harness Basics # Wire Harness Design Best Practices for Engineers 10 min read · Wire Harness Basics A well-designed wire harness is easier to manufacture, cheaper to produce, more reliable in the field, and simpler to service. A poorly designed one causes production delays, drives up costs, and creates field failures that damage your product's reputation. The difference often comes down to a handful of design decisions made early in the process. This guide covers the best practices that experienced harness engineers follow — and the common mistakes that cost OEMs time and money. ## 1. Design for Manufacturability from Day One The single most impactful thing you can do is design your harness with manufacturing in mind — not as an afterthought. This means: - Involve your manufacturer early. Share your concept or preliminary drawings and ask for DFM feedback before the design is finalized. Changes are cheap on paper and expensive in production. - Design for harness board assembly. Most harnesses are built on flat assembly boards with jigs and fixtures. Design your routing so the harness can be laid out, assembled, and removed from a board efficiently. - Minimize unique components. Every unique wire length, connector, or terminal adds complexity. Standardize where possible — use common wire gauges, common connector families, and common terminal types across your harness. ## 2. Get the Wiring Schematic Right The wiring schematic is the foundation of your harness design. Every wire, connector, pin assignment, and splice should be clearly defined. Common schematic issues that cause problems downstream: - Missing pin assignments — which wire goes to which cavity? - Ambiguous wire callouts — gauge, color, and insulation type should all be specified. - Undefined splice locations — where do wires join and what method is used? - Missing fuse and relay specifications — if they're part of the harness, call them out. A clean, complete schematic saves time in quoting, reduces first-article issues, and prevents costly errors in production. ## 3. Choose Connectors Carefully Connector selection has an outsized impact on cost, reliability, and serviceability. Key principles: - Match the connector to the environment. Use sealed connectors (Deutsch DT, Molex MX150, TE Superseal) where moisture, dust, or chemicals are present. Use unsealed connectors (Molex Mini-Fit, JST XH) for protected internal connections. - Don't over-specify. Sealed connectors cost 3–10x more than unsealed equivalents. If the connection is inside a dry enclosure, an unsealed connector is the right choice. - Consider serviceability. Will the harness ever need to be disconnected in the field? Choose connectors with adequate mating cycles and intuitive keying so field techs can't mis-mate them. - Use keying and color coding. Prevent incorrect mating by using different connector sizes, key positions, or housing colors for connectors that could be confused. ## 4. Size Wire Correctly Wire gauge selection affects safety, performance, and cost. Follow these principles: - Size for peak current , not average. Account for motor inrush, transient loads, and worst-case operating conditions. - Calculate voltage drop for long runs, especially in 12V and 24V DC systems where even small drops affect performance. - Apply derating factors for bundled conductors and elevated ambient temperatures. - Standardize gauges where possible. If one circuit needs 18 AWG and another needs 20 AWG, consider using 18 AWG for both to reduce inventory and simplify production. ## 5. Plan Your Routing How the harness is routed through the product directly affects reliability and service life: - Respect minimum bend radii. Use 10x the bundle diameter for dynamic applications, 6x for static. Tight bends fatigue conductors and crack insulation. - Avoid heat sources. Route away from exhaust, engines, and high-temperature components. If proximity is unavoidable, use high-temperature insulation (XLPE, PTFE, silicone) and heat shielding. - Prevent abrasion. Use grommets where the harness passes through sheet metal. Add protective sleeving in areas where the harness contacts sharp edges or moving parts. - Support the harness. Use P-clamps, cable ties, and adhesive mounts at regular intervals to prevent the harness from hanging unsupported. Unsupported weight causes strain at connectors and breakout points. - Plan for service access. Don't bury connectors behind components that have to be removed to access them. Field techs will thank you. ## 6. Specify Proper Strain Relief The cable-to-connector junction is the most vulnerable point in any wire harness. Without proper strain relief, vibration and mechanical stress will fatigue the wire at the termination point, causing intermittent or permanent failures. Options include: - Overmolding — the gold standard. Creates a sealed, reinforced transition between cable and connector. - Backshells and strain relief boots — attach to the connector and support the cable at the exit point. - Heat shrink — provides moderate strain relief and environmental protection. - Cable ties and clamps — secure the cable near the connector to prevent pulling force from reaching the termination. ## 7. Label Everything Proper labeling saves enormous time during installation, testing, and field service. Best practices: - Label every connector with a unique identifier that matches your schematic. - Label individual wires at each end for circuits that will be field-terminated. - Use durable label materials — self-laminating labels, heat-shrink labels, or laser-marked sleeves for harsh environments. - Include the harness part number and revision on the main harness label. ## 8. Define Your Testing Requirements Every wire harness should be electrically tested before it ships. At minimum, specify: - Continuity testing — verify every circuit is complete from end to end. - Short-circuit testing — verify no unintended connections exist between circuits. - Hi-pot / dielectric withstand — for applications requiring insulation integrity verification (common in industrial and medical applications). - Pull-force testing — verify crimp terminations meet minimum retention force requirements. H&L performs 100% end-of-line continuity and short-circuit testing using automated test fixtures with integrated vision systems, plus crimp force monitoring and cross-section analysis. ## 9. Prototype Before Production Never go straight from drawing to production. Build prototypes, install them in your product, test them, and iterate. Prototyping catches: - Routing conflicts you didn't see on the drawing - Wire lengths that are too short or too long - Connector access issues that make installation difficult - Interference with other components - Opportunities to simplify the design H&L supports rapid prototype builds with engineering feedback — so you can validate and improve your design before committing to production tooling and volumes. ## 10. Document Everything A complete documentation package ensures your harness can be built consistently, inspected accurately, and maintained in the field. Your package should include: - Wiring schematic with pin assignments - Harness assembly drawing with dimensions and routing - Bill of materials (BOM) with manufacturer part numbers - Special instructions (torque specs, testing requirements, packaging) - Revision history Design Support from H&L H&L Manufacturing offers SolidWorks design assistance, DFM review, and APQP processes to help engineers optimize their wire harness designs for manufacturability and reliability. From concept through prototype to production, our team is an extension of yours. Send us your drawings and let's build something together. ## Harness Design FAQ Common questions about wire harness design and working with a manufacturer. ### What is Design for Manufacturability (DFM)? DFM is the practice of designing a product so it can be manufactured efficiently, consistently, and at the lowest practical cost. For wire harnesses, this means choosing standard components, simplifying routing, minimizing unique wire lengths, and designing for assembly on a harness board. A good manufacturer will provide DFM feedback during design review. ### What should my wire harness drawing include? A complete drawing should include a wiring schematic, wire callouts (gauge, color, length, part number), connector and terminal part numbers, routing paths, breakout dimensions, labeling requirements, and any special instructions (torque specs, testing requirements, packaging). The more detail you provide, the faster and more accurate the quoting and first-article process. ### How early should I involve my manufacturer in the design process? As early as possible. Engaging your manufacturer during the design phase — not after the drawing is finalized — gives you access to DFM feedback, component recommendations, and cost-saving suggestions that become much harder to implement later. H&L offers SolidWorks design assistance and APQP processes to support early-stage collaboration. ### What is the minimum bend radius for wire harness routing? The general rule is a minimum bend radius of 10x the cable or bundle diameter for dynamic (moving) applications and 6x for static (fixed) installations. Tighter bends stress the conductors and insulation, leading to premature failure. Always check the wire and connector manufacturer's specifications for exact minimums. ### How do I reduce wire harness cost without sacrificing quality? Standardize wire gauges and colors across circuits where possible, use common connector families, minimize the number of unique wire lengths, design for efficient board assembly, and avoid over-specifying (e.g., sealed connectors where unsealed will do). Your manufacturer can identify the biggest cost drivers during design review. ### Should I use a BOM or a drawing to specify my harness? Both. The drawing defines the physical layout, routing, and dimensions. The BOM lists every component with part numbers, quantities, and specifications. Together they give the manufacturer everything needed to quote and build accurately. If you only have one, start there — your manufacturer can help develop the other. ### What wire colors should I use? Follow your industry's color-coding standards if applicable (SAE J1128 for automotive, NEC for building wire). If no standard applies, establish a consistent color code across your product line and document it. Use unique colors or striped wire for circuits that could be confused during installation or service. ### Does H&L offer engineering support for harness design? Yes. H&L provides SolidWorks design assistance, DFM review, APQP processes, and prototype builds with engineering feedback. Our team reviews every design for manufacturability and can recommend improvements to reduce cost, improve reliability, and streamline production. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Wire Harness vs. Cable Assembly: What's the Difference? | H&L Manufacturing URL: https://hlmanufacturing.com/resources/wire-harness-vs-cable-assembly Description: Understand the key differences between wire harnesses and cable assemblies — construction, protection, cost, and when to use each. Resources / Wire Harness Basics # Wire Harness vs. Cable Assembly: What's the Difference? 5 min read · Wire Harness Basics The terms "wire harness" and "cable assembly" are often used interchangeably — but they're not the same thing. While both serve the purpose of organizing and routing electrical connections, they differ in construction, protection level, application, and cost. Understanding the distinction helps engineers and procurement teams specify the right solution for their product. ## Wire Harness: Definition A wire harness is an organized bundle of individual wires, cables, and connectors held together with cable ties, lacing, clamps, or wrapping tape. The individual wires remain visible and identifiable within the bundle. Wire harnesses are designed primarily for internal routing — inside a vehicle body, equipment enclosure, or control panel — where the wiring is protected by the surrounding structure. Wire harnesses are lightweight, flexible, and cost-effective. They make installation faster by pre-grouping wires into a single assembly that can be dropped into position and connected. ## Cable Assembly: Definition A cable assembly encases multiple conductors inside a single protective outer jacket or sheath — typically made of thermoplastic, rubber, vinyl, or shrink tubing. Unlike a wire harness, the individual wires inside a cable assembly are not visible from the outside. The outer jacket provides significantly more protection against environmental hazards. Cable assemblies are built for external or harsh environments — anywhere the wiring is exposed to moisture, chemicals, abrasion, vibration, UV, or extreme temperatures. ## Key Differences at a Glance Feature Wire Harness Cable Assembly Construction Individual wires bundled with ties, tape, or lacing Wires enclosed in a single outer jacket Protection level Basic — relies on surrounding structure High — jacket protects against moisture, abrasion, chemicals Typical use Internal wiring (dashboards, panels, enclosures) External or exposed connections Flexibility Highly flexible — conforms to tight spaces Less flexible due to outer jacket Weight Lighter Heavier Cost Generally lower Higher due to jacketing and materials Environmental resistance Moderate High (moisture, UV, chemical, thermal) ## When to Use Each ### Choose a Wire Harness When: - Wiring is routed inside a protected enclosure, panel, or vehicle body - Space is tight and you need the assembly to conform to complex routing paths - Weight savings and cost efficiency are priorities - The environment is controlled (no significant moisture, chemical, or abrasion exposure) ### Choose a Cable Assembly When: - Wiring is exposed to the elements — rain, dust, UV, chemicals, or physical contact - The connection will be repeatedly plugged and unplugged (high mating cycles) - You need sealed, waterproof, or IP-rated terminations - Vibration, mechanical stress, or high temperatures are factors ## Overmolding: The Best of Both Worlds In many applications, manufacturers use overmolding to add sealed, ruggedized terminations to a wire harness — giving it cable-assembly-level protection at the connection points without the weight and cost of a fully jacketed cable. This is especially common in automotive, agricultural, and outdoor equipment applications. At H&L Manufacturing, we offer overmolding as part of our vertically integrated process, so you can get the right level of protection exactly where you need it — without overbuilding the rest of the assembly. ## The Bottom Line Wire harnesses and cable assemblies solve different problems. A wire harness is your best bet for organized, cost-effective internal wiring. A cable assembly is the right choice when the wiring needs to survive harsh conditions. Many products use both — and sometimes overmolding bridges the gap between the two. The key is understanding your application's requirements and working with a manufacturer who can deliver either solution. Need Help Deciding? H&L Manufacturing builds custom wire harnesses, cable assemblies, and overmolded connections — all in-house at our Middleville, Michigan facility. Send us your application details and our engineering team will recommend the right solution. ## Wire Harness vs. Cable Assembly FAQ Common questions about choosing between wire harnesses and cable assemblies. ### Can a product use both a wire harness and a cable assembly? Yes — many products use both. A wire harness might handle internal routing inside an enclosure, while a cable assembly connects that enclosure to an external component exposed to the elements. The two are complementary, not mutually exclusive. ### Which is more expensive — a wire harness or a cable assembly? Cable assemblies typically cost more per unit due to the added outer jacketing, more rugged connectors, and additional material. Wire harnesses are generally more cost-effective for internal wiring applications where heavy-duty protection isn't required. ### When should I choose a cable assembly over a wire harness? Choose a cable assembly when the wiring will be exposed to moisture, chemicals, UV, extreme temperatures, physical abrasion, or frequent handling. The protective outer jacket provides the durability needed for external and harsh-environment applications. ### When is a wire harness the better choice? A wire harness is ideal for internal applications — inside a vehicle dash, inside a control panel, or within an equipment enclosure — where space optimization, lightweight design, and cost efficiency are priorities. ### Are wire harnesses and cable assemblies tested differently? The core electrical tests — continuity, short circuit, and insulation resistance — are the same. However, cable assemblies for harsh environments may also undergo additional tests like pull-force testing, ingress protection (IP) testing, and environmental stress screening. ### Does H&L manufacture both wire harnesses and cable assemblies? Yes. H&L manufactures custom wire harnesses and cable assemblies, along with overmolded connections for applications requiring sealed, ruggedized terminations. We handle everything from prototype to production. ### What connectors are used in cable assemblies vs. wire harnesses? Wire harnesses commonly use Molex, JST, and TE housings for internal connections. Cable assemblies often use heavier-duty connectors like Deutsch, Amphenol, or mil-spec circular connectors designed for sealing and repeated mating cycles. ### How do I decide which solution I need for my project? Consider the environment (indoor vs. outdoor), mechanical stress, temperature range, moisture exposure, and whether the connection needs to be repeatedly plugged and unplugged. Our engineering team can review your application and recommend the right approach. ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Control Panel Assembly & Wiring | H&L Manufacturing URL: https://hlmanufacturing.com/services/control-panel-assembly Description: Complete control panel builds with wiring, component mounting, labeling, and testing. UL 508A compliant capabilities. Middleville, Michigan. Service — Control Panel Assembly # Control Panel Assembly & Wiring Complete panel builds from schematic to finished, tested assembly. Request a Quote → 01 Service ## Overview H&L Manufacturing builds complete control panels from your schematics and BOMs. Our capabilities include component mounting, wire routing, labeling, point-to-point wiring, HMI validation, and full functional testing. We work with relays, terminal blocks, circuit breakers, HMIs, power supplies, and more. 02 How We Work ## Our Process - 01 ### Schematic Review Review your panel design and bill of materials. - 02 ### Component Procurement Source and kit all required components. - 03 ### Assembly & Wiring Component mounting, wire routing, and labeling. - 04 ### Testing Point-to-point verification and functional testing. - 05 ### Delivery Packaging and on-time shipment. 03 Data Sheet ## Capabilities & Specifications Label Value Standards UL Approved Components Relays, terminal blocks, breakers, HMIs, power supplies Capabilities Component mounting, wire routing, labeling, HMI validation, functional testing ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # General Assembly & Box Build Services | H&L Manufacturing URL: https://hlmanufacturing.com/services/general-assembly Description: Sub-assemblies, box builds, kitting, and turnkey production from H&L Manufacturing in Middleville, Michigan. Service — General Assembly # General Assembly & Box Build Services Sub-assemblies, box builds, kitting, and turnkey production. Request a Quote → 01 Service ## Overview Reduce your internal labor costs and leverage H&L's trained production team for your assembly needs. We handle sub-assemblies, box builds, electro-mechanical assembly, kitting, packaging, and fulfillment. Our flexible production floor scales with your demand, from small batches to high-volume runs. 02 Data Sheet ## Capabilities & Specifications Label Value Services Box builds, sub-assemblies, kitting, electro-mechanical assembly Logistics Kitting, kanban, drop shipping Packaging Custom packaging and fulfillment available Volumes Low to high volume production runs ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Custom Overmolding Services | H&L Manufacturing URL: https://hlmanufacturing.com/services/overmolding Description: Durable, sealed overmolded connectors and assemblies for harsh environments. Custom tooling, Arburg machines. Middleville, Michigan. Service — Overmolding # Custom Overmolding Services Durable, sealed overmolded connectors and assemblies for harsh environments. Request a Quote → 01 Service ## Overview Overmolding adds a protective layer of material around connectors and cable assemblies, providing strain relief, environmental sealing, and enhanced durability. H&L Manufacturing offers custom wire harness molding services. We partner with local mold manufacturers for tooling design and fabrication, ensuring high-quality molds tailored to your specifications. Our vertically integrated facility means your wire harness and overmolding are done under one roof. 02 How We Work ## Our Process - 01 ### Tooling Design Custom mold design for your connector and cable geometry. - 02 ### Mold Fabrication Partnered with local mold manufacturers for precision tooling. - 03 ### Overmolding Precision overmolding with chosen material. - 04 ### Testing Pull testing, IP rating validation, visual inspection. - 05 ### Production Scale to full production volumes. 03 Data Sheet ## Capabilities & Specifications Label Value Connector Compatibility All major connector brands Integration Wire harness and overmolding under one roof ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Rapid Prototyping & 3D Printing | H&L Manufacturing URL: https://hlmanufacturing.com/services/prototyping Description: Rapid prototype builds with engineering feedback. 3D printing for fixtures, jigs, and enclosures. Middleville, Michigan. Service — Prototyping & 3D Printing # Rapid Prototyping & 3D Printing Quick-turn prototypes and additive manufacturing for fixtures, jigs, and enclosures. Request a Quote → 01 Service ## Overview Need to validate your design before committing to production? H&L Manufacturing offers rapid prototyping for wire harnesses and assemblies with engineering feedback included. Our 3D printing capabilities support fixture, jig, enclosure, and test block fabrication — getting you from concept to physical part in days, not weeks. 02 How We Work ## Our Process - 01 ### Design Review Review CAD files and design intent. - 02 ### Material Selection Choose the right material for your application. - 03 ### 3D Print / Build Rapid fabrication with fast turnaround. - 04 ### Validation Fit check, function test, and feedback. - 05 ### Iterate or Scale Refine or transition to production. 03 Data Sheet ## Capabilities & Specifications Label Value Lead Time Prototypes in days, not weeks Applications Fixtures, jigs, enclosures, test blocks, small volume production Design Support SolidWorks design assistance available ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote → --- # Custom Wire Harness Manufacturing | H&L Manufacturing URL: https://hlmanufacturing.com/services/wire-harness-manufacturing Description: Custom wire harnesses from prototype to production. Molex, TE, Deutsch, JST, Amphenol connectors. 100% continuity tested. Middleville, Michigan. Service — Wire Harness # Custom Wire Harness Manufacturing Engineered and built to your exact specifications — from prototype through high-volume production. Request a Quote → 01 Service ## Overview H&L Manufacturing designs and builds custom wire harnesses for a wide range of industries including agriculture, automotive, industrial controls, marine, and industrial equipment. Whether you need a single prototype or thousands of production units, our team has the expertise and equipment to deliver high-quality harnesses on time and to spec. Every harness is 100% continuity tested before shipping. 02 How We Work ## Our Process - 01 ### Design Review & DFM Engineering review of your drawings with design-for-manufacturability feedback. - 02 ### Prototyping Sample builds for fit, form, and function validation. - 03 ### Testing & Validation Pull testing, continuity testing, and vision camera inspection. APQP and PPAP documentation provided. - 04 ### Production Setup Tooling, jigs, and process documentation for consistent builds. - 05 ### QC & Shipping Final inspection, packaging, and on-time delivery. 03 Data Sheet ## Capabilities & Specifications Label Value Connector Brands Molex, TE Connectivity, Deutsch, JST, Amphenol, Custom Termination Types Crimp, solder, IDC, ultrasonic weld Testing EOL Continuity/Short Testing w/ Integrated Vision Systems, Crimp Force Monitoring, Cross-Section Analysis Volumes Prototype through high-volume production Additional Services Harness retrofit/repair, kitting, kanban, drop shipping Design Support SolidWorks design assistance, APQP process fitted to customer needs ## Get a Quote for Your Project Send us your specs and we'll be in touch shortly with confirmation of your request. Request a Quote →