Cable Harness
Cable and wire harness assemblies connect power, signals, and components throughout an electronic product. FCS supports custom interconnect requirements, from standalone harnesses to designs that combine cables, connectors, and flexible circuits.
We work with OEMs and contract manufacturers to review connector selection, wire and cable requirements, routing, shielding, strain relief, and test needs. Our team supports new designs from prototype through production, as well as second-source evaluation for existing assemblies. With North American commercial and engineering support, FCS helps coordinate DFM, quoting, technical communication, and the path into manufacturing.
Have a cable or wire harness design to review?
A cable or wire harness must do more than connect two points. It needs to fit the available space, carry the required power or signals, withstand its operating environment, and be practical to assemble and test. FCS works with customers to review these requirements early, including projects that combine cable or wire harness assemblies with flexible printed circuits.
Electrical requirements: We review conductor size, current needs, signal types, cable construction, and shielding or grounding requirements to help determine the appropriate wire, cable, and termination approach.
Connectors and terminations: We evaluate connector types, pin assignments, crimp or solder terminations, and the requirements at each connection point. These choices affect mating, installation, and service access.
Routing and packaging: Harness length, branch locations, bend paths, and available space influence how the assembly will be routed, secured, and installed within the product.
Mechanical protection: Depending on the application, a harness may need strain relief, sleeving, overmolding, or other protection. We consider movement, vibration, handling, and environmental exposure.
Cable-to-FPC integration: FCS supports assemblies that connect cables or wire harnesses directly to flexible printed circuits. We review the connection method, pad and termination design, strain relief, routing, and inspection requirements so the cable and flex circuit can function as one integrated assembly.
Inspection and testing: Continuity checks, pinout verification, and other electrical or visual inspections should reflect the assembly’s requirements. We work with customers to define appropriate acceptance and test criteria.
Production and second sourcing: For an existing harness, we review drawings, bills of materials, connector availability, and test requirements to identify what is needed to reproduce and qualify the assembly. For new designs, those same details help establish a path from prototype to production.
FCS helps customers develop interconnect assemblies that can be built consistently and integrated into the finished product, with North American commercial and engineering coordination throughout design review, quoting, and production.
Cable & Wire Harness Design Support
Cable & Wire Harness Applications We Support
Cable and wire harness assemblies carry power and signals between components throughout a product. FCS supports standalone harnesses as well as assemblies that integrate cables with flexible printed circuits for applications such as:
Medical devices: Diagnostic and imaging equipment, endoscopy systems, surgical robotics, patient monitoring, and other devices with demanding routing or connection requirements.
Aerospace and defense: UAV systems, instrumentation, displays, and communications equipment, subject to each program’s sourcing and quality requirements.
Automotive: Sensors, lighting, controls, and connections between electronic modules.
Industrial equipment: Robotics, automation systems, measurement devices, and machine controls.
Commercial electronics: Displays, communications products, and compact devices that require custom internal interconnects.
Each application has different electrical, mechanical, and test requirements. We review those details with the customer to determine the appropriate harness construction and whether cable-to-FPC integration would add value.
