High-Quality Car Wiring Harness Customization Case Study

Suzhou Simatec Wire Harness Co., Ltd. is a professional developer and manufacturer of high-end customized wire harnesses, including industrial, medical, automotive, and new energy wire harnesses. We have a vibrant and energetic young R&D team. Today, we introduce the production process of automotive wire harness connectors. Automotive wire harnesses are the backbone of the vehicle's electrical circuitry, forming a network for the product. Without wire harnesses, there would be no automotive electrical circuits. So, how are automotive wire harnesses made?

Generally, it mainly involves three processes: drawing, twisting, and covering.

Specific steps, let's get to know them together with the editor from Suzhou Simaitex Wiring Manufacturer.

Firstly, covering. Depending on the different functional conditions of wires and cables, specialized equipment is used to cover the conductors with various materials. Specifically, it can be categorized into wrapping → longitudinal wrapping → extrusion → dipping, etc. The details are as follows:

Sheathing: Mica tape, non-woven fabric, strip paper, plastic bags, and alkali-free glass fiber tape. In addition, there are fiber materials such as yarn and cotton yarn.

Coating: Wrinkled aluminum strip and rubber materials.

Compressed Packaging: Lead, plastic, rubber, aluminum, and other materials.

Coating: Insulating paints, asphalt, etc.

Next, stranding. The stranding process typically includes conductor stranding, weaving, wrapping, cable forming, and steel wire armor, among others. To enhance the overall flexibility and tensile strength of electrical cables, multiple single wires can be interwoven according to specific directions, which is referred to as stranding.

Metal drawing involves two types: single fiber drawing and twisted drawing. In metal pressure processing, under the action of external force, metal is forcibly passed through molds (pressure rolls), resulting in the reduction of its cross-sectional area and achieving the desired cross-sectional shape and size. This processing method is known as metal drawing.