Design Support
Wire harness and cable assembly design services. From concept to production-ready designs, our engineers help you develop optimal solutions.
Design Services
Engineering support throughout your design and development process.
Concept Development
Work from your initial concept to develop a manufacturable design
DFM Analysis
Design for Manufacturing review to optimize production efficiency
Connector Selection
Help selecting optimal connectors for your application
Wire Sizing
Proper wire gauge calculations for current and voltage drop
Drawing Creation
Complete manufacturing drawings and documentation
Prototyping
Rapid prototypes for design validation and testing
Design Process
A collaborative process from concept to production.
Share Your Requirements
Send us your concept, sketch, sample, or partial specifications. We can work from any starting point.
Engineering Review
Our engineers analyze your requirements and provide recommendations for optimal design.
Design Development
We develop detailed drawings, BOM, and documentation for manufacturing.
Customer Approval
Review and approve the design before production begins.
Prototype
Build prototypes for physical validation and testing.
Production
Move to production with approved design and documentation.
DFM Optimization
Design for Manufacturing (DFM) analysis helps optimize your design for efficient production. We review designs and provide recommendations to reduce cost and improve quality.
- Connector consolidation opportunities
- Wire gauge optimization
- Assembly process simplification
- Material availability review
- Cost reduction recommendations
- Quality improvement suggestions
- Lead time considerations
- Standardization opportunities
What to Share With Us
Any Starting Point
- Hand sketches or concepts
- Existing drawings (any format)
- Physical samples
- Photos or descriptions
- Functional requirements
Helpful Information
- Application description
- Environmental conditions
- Voltage and current requirements
- Connector preferences
- Target cost (if applicable)
Don't have detailed specifications? No problem - we can help develop them based on your application needs.
Wire Harness Design Support and Engineering Services
As a specialized wire harness design partner, OurPCB delivers engineering support from concept to production for wire harness and cable assembly applications. Our design services include DFM analysis, connector selection, wire sizing, drawing creation, and 48-hour prototyping.
Design for Manufacturing (DFM) review optimizes your design for efficient production. Connector consolidation, wire gauge optimization, and assembly simplification reduce cost and improve quality. We recommend appropriate connectors for automotive, medical, aerospace, and industrial applications.
Wire sizing calculations ensure proper current capacity and voltage drop. CAD drawing creation provides complete manufacturing documentation. Our engineers work from any starting point—sketches, concepts, samples, or partial specifications. Custom wire harness designs evolve through collaborative review.
Prototyping validates designs before production commitment. Rapid prototypes enable physical testing and customer approval. Tooling development for assembly boards and test fixtures supports production transition. Our testing capabilities verify prototype performance.
Basic design support is included with your quotation—connector recommendations, wire sizing, and DFM feedback at no charge. ISO 9001 quality systems ensure design documentation meets manufacturing requirements. Contact our engineering team to discuss design support for your wire harness project.
Design Support FAQ
That's fine - we regularly work with customers who have only a concept or basic requirements. Our engineers can help develop your concept into a manufacturable design, selecting appropriate connectors, wires, and construction methods based on your application needs.
Basic design assistance is included with your quotation and order. This includes connector recommendations, wire sizing, and DFM feedback. For extensive design work or custom drawing creation, there may be engineering charges, but these are typically waived when the order is placed.
Yes, we can reverse-engineer samples to create manufacturing documentation. This is helpful when you need an alternative source or improvements to an existing design. We maintain confidentiality and focus on providing equal or better alternatives.
We accept drawings in any format including PDF, DWG, DXF, SolidWorks, hand sketches, or photos. We provide manufacturing drawings in PDF format and can provide CAD files upon request. Our drawings include all information needed for manufacturing and quality inspection.
Need Design Assistance?
From concept to production-ready design, our engineering team helps you develop optimal wire harness and cable assembly solutions.