Custom Complex Multi-Branch Harnesses

Where Precision Engineering Meets Complex Integration

Modern systems in aerospace, industrial automation, and advanced vehicles are more integrated than ever, requiring a single harness to route power, data, and signals to dozens of different points. Cablum Cable excels in the design and manufacture of these highly complex, multi-branch wire harnesses. We combine meticulous hand-assembly with automated precision to create intricate yet reliable interconnect solutions that form the central nervous system of your most advanced products. Our expertise transforms a tangled web of potential failure points into a streamlined, durable, and easily-installable assembly.

It's More Than Just Wires

Creating a complex harness is a multi-disciplinary engineering challenge. It begins with our DFM (Design for Manufacturability) process, where we analyze your initial concept or drawing. Our engineers provide critical feedback on component selection, suggesting connectors that are better suited for manufacturability or offer improved reliability. We focus on the routing path, ensuring that branch lengths are precise to avoid excess slack or tension during final installation. We also plan the strategic placement of mounting hardware, such as clips, clamps, and grommets, which are essential for securing the harness within the final product and protecting it from abrasion and vibration.

The Assembly Board: A Blueprint for Precision

For every complex harness, we create a full-scale 1:1 assembly board, or nailboard. This board serves as a physical blueprint for our assembly technicians. It lays out the exact path of every wire and every branch, with nails or pegs indicating the precise locations for breakouts, connectors, and mounting points. This meticulous preparation ensures that every harness built is identical to the last, maintaining unparalleled consistency across production runs. Technicians route the wires according to this guide, apply protective coverings like convoluted tubing or braided sleeving, and terminate the vast array of connectors required. This disciplined, blueprint-driven approach is the only way to guarantee the quality and repeatability of such intricate assemblies.