Wire Harness Manufacturing Process – A Step by Step Guide

By | Date posted: | Last updated: February 14, 2022
wire-harness-manufacturing-process

The demand for wire harnesses continues to grow and with it we need to understand the manufacturing process of this critical component in detail. Before we offer a step-by-step guide to the manufacturing process, let us look at what wire harness assemblies are and what are the benefits of their use.

What are Wire Harness Assemblies?

Simply put wire harness assemblies are the bundled processed wires with a protective sheath. Harnesses are important as they organize wires for easy implementation. They are different from cable assemblies in that cable assemblies bind multiple covered wires with a covering to provide protection in harsh environments. Make the right choice between cable assemblies and wire harness assemblies.

The benefits of wire harness assemblies include:

  • They help optimize space.
  • They help in customization basis the bespoke need of the appliance.
  • They help in improving equipment safety.
  • They improve the life of custom cable assemblies and wires.

Wire Harnesses find extensive application in a wide variety of appliances including but not limited to:

  • Automotive
  • Flight Simulators
  • Panel Displays
  • Heavy equipment and more

Step-By-Step Guide of the Wire Harness Manufacturing Process:

Wire Harness Design

The manufacturing process, of course, begins with the design aspect. The wire harness needs to be custom designed for each product. What is also imperative is to choose the components of the harness carefully and be mindful of all specifications.

Wire Harness Prototyping

Since the wire harness plays a critical role, prior testing is mandatory. What this means, is to create a functional prototype so that the harness can be tested in its intended application. This way you can be sure about the harness before beginning the first production run and there are no costly errors to contend with at a later date.

Wire Harness Production & Assembly

The production of the wire harness leaves little room for error, so all design specifications need to be met. It is important to remember that despite some level of automation, the manual assembly still plays an important role in the wire harness manufacturing process. This is on account of the fact, that wire harnesses and cable assemblies involve some intricate steps that need manual intervention. Since wire harnesses need to be customized for individual applications, the role of manual assembly further increases. They resolve geometric and electrical issues in the products. They also ground and protect wires from both external and internal damage. Also, the advantage of manual production is its cost-effectiveness.

Broadly speaking, the steps involved in building the wire harness involve:

  • Cutting the wires to the right length with a wire cutting machine.
  • Stripping the wire ends to be able to attach the terminals or connectors.
  • Gathering the wire into a harness meeting the design specifications. Manual processes involve routing the wires through the sleeves, crimping the terminals onto the wires, insertion of one sleeve into the other, fastening strands etc.
  • There is some amount of automation involved too as cutting machines are used to cut the wires to specified lengths. The use of machines is also in crimping terminals. Besides, solder machines are used to seal the wire ends.

Wire Harness Testing

Post production, comes the important stage of testing where each wire harness goes through a process of safety testing. This is a crucial process as it ensures that the product performs up to its potential. The harness needs to be checked for continuity as also for construction and labeling.

To sum up

It is important to remember that the more detailed your documentation is the fewer issues will be faced on the assembly floor. Some of the information that should be provided to the contract manufacturer includes:

  • Detailed images of connectors along with the pin locations
  • Wire lists
  • Bill of Materials
  • Assembly Drawing
  • Testing Specifications

The contract manufacturer will be in a position to offer a number of recommendations to do with the following aspects:

  • Termination recommendations on how the wires should be attached- such as stripped and bare or stripped and tinned.
  • Torque values on wire harness components and fasteners.

It is advisable that you give generic specifications for the wires. That way the PCB manufacturer can go with what works best for the harness and what is cost-effective. With due attention paid to the above issues you can ensure that you help speed the overall manufacturing process as also receive a quality product.

At Technotronix, we have 40 years of experience in manufacturing and assembling industry-leading printed circuit boards, cable, and wire harness assemblies. Equipped with state-of-the-art equipment and skilled personnel, we offer wire harness assemblies to meet your bespoke requirements. Technotronix can be your trusted PCB manufacturer who will give you ample smart solutions related to printed circuit boards.

Top 10 Myths and Facts about selecting the Electronic Contract Manufacturing Partner

By | Date posted: | Last updated: October 29, 2021
Electronic Contract Manufacturing

With outsourcing playing a significant role in electronics manufacturing, the choice of the right partner becomes an important determinant of success. However, there are several myths that exist when it comes to the choice of electronic contract manufacturer. About we debunk these myths and unearth the real facts that help you make the right choice. So here goes:

#Myth 1

Technical competence is the only thing to look for in an electronic contract manufacturing partner

While clearly, technical competence is an important aspect of the choice of an electronic contract manufacturer, but it clearly isn’t the only factor. The mistake most people make is that many other business factors are ignored when making the choice. It is important to remember that working with an electronic contract manufacturing partner is a complex business relationship not just a technical one.

#Myth 2

A better presentation is equivalent to a superior contract manufacturer

Let us face it, an impressive presentation may be a function of the excellent sales and marketing capabilities of the contract manufacturer. It is extremely important that while you go by the presentation as an indicator, you also judge the other capabilities of the PCB contract manufacturer namely its operations expertise. It is absolutely imperative that you also do a robust reference check before coming to any decision.

#Myth 3

Larger Companies will charge a lower Value-Added Margin

Once again, while this may be true sometimes, it isn’t a universally held premise. This is because while large electronic contract manufacturers may get a volume discount on their raw material requirements, labor costs may or may not follow the same practice.

#Myth 4

If the manufacturer has a good vertical integration model in place it can offer low prices

This too isn’t always a given. There are electronic contract manufacturers who could do this and then again, there are others who could have a disintegrated supply chain and yet could offer you competitive prices.

#Myth 5

You need to go with a partner that also invests in your business.

Well, not necessarily. Besides, there may not be any critical advantage that you may necessarily reap from the partnership. Not to mention the fact that if the electronic contract manufacturer loses any money building products for you, the partnership will break anyway.

#Myth 6

The electronic contract manufacturer should not be working for my competitor

Your fear may be totally unfounded. As long as the electronic contract manufacturer is compatible with your overall project that also works with your competitor shouldn’t affect your decision. Professional contract manufacturers will certainly be totally conscious of the proprietary nature of the PCB manufacturing processes. It is also worth remembering that electronic contract manufacturers who work extensively in your industry will also have access to industry’s best practices that will stand you in good stead and ensure that you don’t have to reinvent the wheel.

#Myth 7

I need to necessarily go with a “Tier 1” contract manufacturer

Bigger isn’t always better! The important bit is to find the right fit in terms of:

  • Volumes
  • Technology
  • Working style
  • Geography
  • Experience, and more.

As long as you find the right size, super size may be inconsequential.

#Myth 8

Lowest price must be the final decision-making criteria

Well, everything else being equal, the above statement holds true. Sometimes, however, you may land up deciding basis a low per unit price and may discover some hidden costs later. In that case, the economics may not work out as well as you had hoped them to.

#Myth 9

I need to partner with multiple electronic contract manufacturers

While this strategy may be based on the perspective of spreading out the risk, it comes with multiple downsides. The most obvious one being that it results in managing multiple relationships and the many problems it brings, a potent one being issues in communication. Also, with multiple partners there is also the fear of timelines of one derailing the entire project.

#Myth 10

If I select the right electronic contract manufacturer there is nothing more that I need to do

Much as it is important to choose the right contract manufacturer, it is equally important to manage the relationship to reap significant results. Also, you need to represent the better plan, strategy and challenges for the best results. An electronic contract manufacturer is the one who can help you out with the product operation. Maintaining a fruitful relationship with your contract manufacturer is the thing you need to do to enjoy the relationship.

With 40 years of experience in the field, a PCB contract manufacturer can be your trusted partner in making available the right components, through a network of component manufacturers.

As a leading electronics contract manufacturer, Technotronix provides a one-stop solution for electronics manufacturing services which includes PCB fabrication and PCB assembly, turnkey, build-box, quick turn prototyping, high mix low volume and high-volume, manufacturing solution, new product introduction, BGA work, engineering support, testing and other services that mainly require by OEMs (Original Equipment Manufacturers). From initial manufacturing, design, development, to full-scale production and after-market support, Technotronix can provide you with a complete package of industrial electronics manufacturing. In case if you have any questions, please feel free to contact us via email at sales@technotronix.us or call us at 714/630-9200.

Top Things you should know about RoHS Compliant Circuit Boards

By | Date posted: | Last updated: August 27, 2021
RoHS compliant circuit boards

Let us begin with a brief introduction to RoHS compliance before we delve into the aspects that one must know about RoHS compliant circuit boards.

A Brief Introduction to RoHS Compliance

The Restriction of Hazardous Substances Compliance, popularly known as RoHS or Directive 2002/95/EC, are a set of standards that restrict the use of hazardous and toxic materials in electronic products sold or distributed in the European Union.

Any OEM (Original Equipment Manufacturer) who manufacturers and sells electronic products or components such as printed circuit boards (PCBs) directly to European clients or support the EU-based integrators, distributors, and resellers need to adhere to this compliance.

The compliance specifies some restricted material as also the maximum levels of these restricted materials in the PCBs and other electronics items as under:

  • Mercury (Hg): < 100 ppm
  • Lead (Pb): < 1000 ppm
  • Cadmium (Cd): < 100 ppm
  • Polybrominated Biphenyls (PBB): < 1000 ppm
  • Hexavalent Chromium: (Cr VI) < 1000 ppm
  • Polybrominated Diphenyl Ethers (PBDE): < 1000 ppm
  • Bis(2-Ethylhexyl) phthalate (DEHP): < 1000 ppm
  • Dibutyl phthalate (DBP): < 1000 ppm
  • Diisobutyl phthalate (DIBP): < 1000 ppm
  • Benzyl butyl phthalate (BBP): < 1000 ppm

Key Principles of RoHS-Compliant Manufacturing of PCBs

There are 3 key concepts that are basic to RoHS-compliant PCB manufacturing:

Material

The first thing to know when it comes to a RoHS-compliant PCB is the use of material. It is critical that the materials used in the assembly of the board are RoHS compliant, in accordance to the regulation. This also includes paying attention to using RoHS compliant substrate materials, lead-free surface finishes, lead free wave soldering and other such services.

The most widely used surface finishes when it comes to lead free boards include:

  • ENIG
  • Immersion Silver
  • Immersion Tin
  • OSP
  • Lead free HASL

Each of them, of course, comes with their own distinct set of advantages and disadvantages.

Processes

Other than the use of PCB Materials, it is important to have the correct processes in place. Such processes can go a long way in keeping RoHS & non-RoHS material separate.

Documentation

The materials as well as the processes need to be documented correctly so as to show that your PCB meets the regulatory requirements.

Benefits of Using RoHS-Compliant PCBs

Some of the major benefits of RoHS-Compliant PCBs include:

Reduction of Metal Poisoning

With obsolescence in technology growing at an alarming rate, so is electronic equipment that is finding place in landfills. Made up of various hazardous materials, that they impact the environment is a given. With the RoHS directive, the impact on both the environment and hence the people is going to be contained. What we will definitely get is a greener environment.

Safe Products

With electronics manufacturers following the RoHS compliance, what users get are non-hazardous products that are safe to use.

Better Thermal properties

Lead-free PCBs have improved thermal properties. Typically they can withstand temperatures between -45°C to 145°C. In fact, with the use of halogen-free laminates the thermal stability can be improved up to 300 degree Centigrade.

What is some of the information that should be added to the PCB fabrication document to ensure the boards are fabricated to be RoHS compliant?

Typically the following details will tell the manufacturer that you are looking for RoHS compliant boards:

  • Explicitly stating that you require the boards to meet with the EU RoHS directive.
  • Stating the type of material needed and any tolerances that you expect the material to meet.
  • Listing the preferred laminates.

How do companies get RoHS compliant certification?

Checkout the following steps are involved for RoHS certification:

  • Documentation Review: A review of Bill of Materials, assembly drawings, Materials Declarations for each component and product, test reports and Conformance Certificates is undertaken at this stage.
  • Audit: Inspection of all manufacturing processes needed to meet RoHS compliance for the restricted substances is undertaken.
  • Testing: On-site portable XRF testing is done to determine values of the restricted RoHS substances.
  • Certification: After the audit is successfully completed, a RoHS certificate is issued.

To sum up
RoHS compliant PCBs can go a long way towards creating a green future. It is therefore important to approach a trust RoHS complaint PCB partner that offers reliable products.

Technotronix is one of the leading printed circuit boards manufacturers in the USA, providing Lead-Free and RoHS Compliant manufacturing solutions. Whether your requirement is for prototypes or large production runs, we have you covered. In fact, we also offer turnkey services, which fully take the hassle of you and allow you to focus on your core business.
Email us on sales@technotronix.us or call us on 714/630-9200 to solve your queries related to our RoHS PCB services.

Get a quick RoHS Circuit Boards Fabrication quote.

What is the Importance of Thermal Pads in Circuit Board Manufacturing?

By | Date posted: | Last updated: February 14, 2022
circuit-board-manufacturing

With the increased miniaturization of devices, the one thing that PCB manufacturers need to contend with is the generation of heat. Thermal management, therefore, becomes an important aspect especially since elevated temperatures make it difficult for the PCB to achieve its target performance and reliability levels.

Thermal Analysis

It is imperative that a detailed thermal analysis be undertaken. Simply put, thermal analysis refers to the process of establishing the thermal module of components and set simulation control parameters according to the structure as well as a raw material of the PCBs, package type of components as well as the operating environment of the PCB. A thorough thermal analysis undertaken in the concept phase will ensure that the exact values of component temperature, board temperature and airflow temperature are obtained, and effective heat dissipation techniques are therefore employed.

Good PCB Design Practice

Some of the PCB design and prototyping techniques that come in handy when it comes to thermal management include:

  • Use of Heat sinks
  • Use of thermal pads and thermal paste.
  • Use of solid filled vias
  • Using board material that has good thermal properties
  • Cooling fans placed strategically

While a heat sink is a preferred device that helps dissipate the heat, however, to ensure better connectivity between the IC and the heat sink, thermal pads and thermal pastes are used.

Let us look a little closely at these two heat-dissipating components.

What are thermal pads and thermal paste?

Thermal pad

Simply put, a thermal pad is a large metal area on which a heat sink can be bolted. Thermal pads made up of thermally conductive material. When placed between the components and the heat sink, they help to dissipate heat easily.

The advantages of using thermal pads include:

  • They can be deployed easily
  • The material can be cut to the bespoke size required
  • They are available in a wide range of materials

However, they can turn out to be expensive. Also, cutting and fitting the material will need effort and time.

Thermal paste

In essence, the thermal paste performs the same function as a thermal pad. The principle that it works on is that it closes any air gaps between the heat generating components and the heat sink. This ensures that the air gaps do not act as thermal insulators and the heat is dissipated easily. There are a wide variety of factors that influence the choice of thermal paste. Some of the factors that go into the selection include:

  • Thermal Conductivity
  • Viscosity
  • Pump-out resiliency
  • Dry-out resiliency

The advantages of using thermal paste includes:

  • It is inexpensive.
  • Its application is fairly easy.
  • It is more durable as compared to a thermal pad as also sturdier.

However, the application of the paste can be a messy affair. Also, the thermal paste does not have as much strength as a thermal pad.

What works better – thermal pad or thermal paste?

There really isn’t a one-size-fits-all answer to that. The choice of one versus the other is really dependent on the application and the bespoke needs of the board. In certain application the use of both is prudent. Typically thermal paste is preferred where:

  • The PCB has high component density
  • The PCB has power components
  • The PCB thermal profile shows thermal hotspots

What is a thermal relief pad?

While discussing heat dissipation techniques, it will also be prudent to touch upon the subject of thermal relief. Essentially, it is a technique used by PCB manufacturer that involves thermally separating solder pads from large copper areas so that excessive heat transfer does not occur from the pads during the soldering process that could result in a delay in melting of the soldering alloy. While its advantages from the Circuit Board Manufacturing standpoint are known, there are concerns regarding the under-utilization of heat transfer capability of large copper areas. In turn, this might lead to localized thermal hot spots at component terminals.

To sum up
To sum up, thermal management of the PCB involves several aspects including but not limited to:

  • Design of power planes
  • Trace Routing
  • Via Placement
  • Thermal Relief Pads and more

Experienced designers can go a long way in ensuring an efficient PCB design that ensures efficient thermal management.

Technotronix is one of the leading PCB (Printed Circuit Boards) manufacturers in the USA. We have over 4 decades of experience in providing innovative PCB manufacturing services using modern technologies and the latest machinery. We are adhering to strict high-quality standards and compliant with the RoHS (Restrictions of Hazardous Substance) directives. We can fulfil the varied needs of our customers from the simple board to the most complex board for PCB prototype to production.

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