How To Design Reliable And Cost-Effective Cable Harnesses?

While concentrating on all the elements of designing a cable harness, the element of cost-effectiveness is generally left behind. However, in today’s overly competitive market, it is good to provide high quality cable harnesses, but it must also not be forgotten that customers are demanding for profit margins too. They are constantly pressurizing cable harness manufacturers to lower their costs while providing quality. If this is what you are looking for too, you can approach Miracle Electronics, one of the very few cable harness manufacturers in India who can provide reliability and cost-effectiveness in a single package of cable harness.

How To Design Reliable And Cost-Effective Cable Harnesses - Miracke Electronics

The two basic types of costs that are involved in the construction of cable harnesses include manufacturing costs and material costs, which are both also responsible for deciding the long term reliability of a harness. To decide upon these costs and their value, factors like types of wires, types of connectors, types of cable ties, types of labels, shielding, jacketing, placement of cable ties, placement of labels, and overall tolerances play very important roles. Let us learn in detail about these elements that can add unnecessary costs or complexities to a cable harness that will ultimately affect the overall price.


Although the cost of wiring tends to be quite low compared to the total cost of a wire harness, they do add a cost element. This is why while picking out a wire, you need to consider whether you are to use the expensive Teflon, or a much inexpensive PVC wire will do. You can also check for other specially customized options regarding voltage, temperature rating, special wire colouring, strand count, etc. Also, at times, cables are needed to be used instead of wires. This will add to the material costs and requires more manual labour to strip and crimp.


Both soldering and crimping have their own advantages, but crimping is much more cost-effective as compared to soldering. This is because crimping requires lesser labour time and operator training.


External protection is of utmost importance for a cable harness. So, what type of external protection is required? Installing a shrink tube or braided loom requires terminals and connectors to be installed after shielding, which requires additional hand labour, thus increasing costs.

Cable ties

You need to ask a few questions when it comes to determining the tie wraps required. How many tie wraps do you need? What types of tie wraps are needed? At what spacing are the tie wraps needed? All these questions can determine that labour required, and thus the costs.


The material cost of a label can vary, but all of them require labour for printing and applying. Also, the costs of the labels may be very small as compared to the costs of applying them. Other elements like the type of labels and the placement of labels can define the costs too. For example, wrap around labels are quite inexpensive as compare to shrink labels. Furthermore, it is very essential that each wire is located properly and connected to the harness in the appropriate location, which again can be labour intensive and costly.


Generally, designers take up the safe path of using tight tolerances on cable harness designs. But, wire harnesses are flexible, which means that tight tolerance is not required. In fact, tighter the tolerance, the more difficult it becomes to manufacture the harness, thus making it more expensive.


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