Wire Harness Solutions for 10 Key Industries: Requirements & Standards

A wire harness for a pacemaker has almost nothing in common with one for a construction excavator—except they're both bundles of wires that need to work flawlessly. The materials, testing, certifications, and design philosophy are completely different.

After 15 years of building harnesses across virtually every industry, I've developed a deep appreciation for these differences. This guide breaks down what makes each industry unique, the certifications you'll need, and the common pitfalls we help customers avoid.

1. Automotive

Automotive wire harnesses are the nervous system of modern vehicles—connecting everything from engine sensors to infotainment systems. A typical vehicle contains 40+ kilometers of wiring and over 700 connectors.

Key Requirements:

Subsystems we serve: Engine harnesses, instrument panels, door modules, sensor connections, lighting systems, and HVAC controls.

2. Medical Devices

Medical cable assemblies face the most stringent requirements of any industry. When a cable connects to life-sustaining or life-saving equipment, there's zero tolerance for failure.

Critical Considerations:

• Biocompatibility: Patient-contact cables must use biocompatible materials (ISO 10993 tested)
• Sterilization: Cables may need to withstand autoclave (steam), EtO, or gamma sterilization
• EMI immunity: Critical for devices near MRI or surgical equipment
• Flexibility: Patient cables need high flex life without signal degradation
• Cleanability: Surfaces must withstand hospital disinfectants

Certification: Our ISO 13485 certification demonstrates our quality system meets medical device manufacturing requirements. We support Class I, II, and III device manufacturers.

3. Aerospace & Aviation

Aerospace wiring operates in extreme conditions—high altitude pressure differentials, wide temperature swings, constant vibration, and zero opportunity for field repair during flight.

Aerospace Standards:

• Wire specification: MIL-W-22759 (ETFE insulation) or MIL-W-81044 (crosslinked)
• Connectors: MIL-DTL-38999 circular connectors with EMI/EMP protection
• Crimping: MIL-STD-1553 compliant crimp specifications
• Documentation: Full material traceability, first article inspection reports

Weight is critical—we help optimize designs using smaller gauge wire where current ratings allow and specifying lightweight aluminum shielding where copper isn't mandatory.

4. Industrial Control & Automation

Industrial control harnesses connect PLCs, sensors, actuators, and HMIs in factory environments. These harnesses face oil, coolants, electromagnetic interference, and constant vibration from nearby machinery.

Common Requirements:

• IP ratings: IP65 to IP67 for protection against water jets and dust
• Connectors: M12 and M8 industrial standards
• EMC: Shielded cables for noise-sensitive signal transmission
• Chemical resistance: PUR or PVC jackets rated for specific oil types

We work with brands like Phoenix Contact and WAGO for terminal block solutions that simplify field installation and troubleshooting.

5. Robotics & Motion Control

Robotics cables face perhaps the most demanding flex requirements of any industry. A robot arm cable might flex millions of times over its service life—and every flex is a potential failure point.

High-Flex Specifications:

Our high-flex cable assemblies use specialized conductor constructions (fine-stranded copper with specific lay lengths) and jacket materials designed for continuous bending.

6. Electric Vehicles & New Energy

EV and new energy applications have transformed the wire harness industry. High-voltage battery systems, charging infrastructure, and solar installations require specialized high-voltage harnesses that didn't exist a decade ago.

EV-Specific Requirements:

• Voltage class: 400V and 800V battery systems require orange-jacketed cables per safety standards
• Shielding: EMI shielding critical around power electronics
• Thermal management: High-temperature ratings near battery packs and inverters
• Safety: Interlock circuits, pilot/proximity lines for charging systems
• Connectors: Anderson, Amphenol high-voltage series

7. Marine

Marine wire harnesses battle salt water, UV exposure, and constant vibration. Corrosion is the enemy—a single exposed copper strand will corrode and eventually fail.

Marine Specifications:

• Wire type: Tinned copper conductors (corrosion resistance)
• Insulation: UV-stabilized, oil-resistant materials
• Connectors: IP68 sealed connectors
• Standards: ABYC (American Boat & Yacht Council), USCG requirements

8. Agriculture

Agricultural equipment harnesses operate in dusty fields, through mud, and under blazing sun. They need to survive seasons of abuse with minimal maintenance.

The demands are similar to heavy construction: Deutsch sealed connectors, heavy-wall tubing protection, and strain relief at every stress point. GPS, precision agriculture sensors, and ISOBUS communication add modern connectivity requirements.

9. Telecommunications

Telecom cable assemblies prioritize signal integrity. Whether it's fiber optic, coaxial RF, or high-speed Ethernet, maintaining signal quality across distance is the fundamental challenge.

Signal Integrity Factors:

• Impedance control: Precise 50Ω or 75Ω for RF applications
• Shielding: Double or triple shielding for EMI rejection
• Connector quality: RF connectors with tight VSWR specifications
• Testing: Network analysis, time-domain reflectometry

10. Defense & Military

Military wire harnesses combine the toughest requirements from other industries: aerospace reliability, marine corrosion resistance, industrial ruggedness, and extensive documentation.

MIL-SPEC Requirements:

• Connectors: MIL-DTL-38999, MIL-DTL-5015 circular connectors
• Wire: MIL-W-22759, MIL-W-81044 specifications
• Workmanship: NASA-STD-8739.4 or equivalent
• Testing: Environmental stress screening, shock & vibration
• Documentation: Full lot traceability, first article inspection

Working Across Industries

Our cross-industry experience is an advantage for customers. Solutions developed for automotive temperature extremes can apply to oil & gas. Medical cleanliness requirements inform semiconductor cleanroom harnesses. Aerospace weight optimization techniques help robotic applications.

Whether your project falls neatly into one category or spans multiple industries, our engineering team can navigate the requirements and deliver the right solution.