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A wire harness can be built with the highest quality copper, perfectly crimped terminals, and extreme-temperature insulation. Yet, it can still fail within weeks if one crucial mechanical feature is ignored. Understanding why strain relief is critical for connector longevity is the difference between a professional wire harness and an amateur one. Strain relief is […]
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For decades, if you needed to permanently join two wires together, you reached for a soldering iron. However, if you look inside the wire harness of any modern automobile or aerospace vehicle, you will rarely find solder. Instead, you will find solid blocks of fused copper. Understanding why ultrasonically welded splices are superior to solder […]
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When a wire harness fails, the vast majority of the time, the failure point is not the wire itself, but the connection at the end of the wire. Mastering proper wire crimping techniques is the single most important skill in wire harness manufacturing. Unlike soldering, which can become brittle and crack under vibration, a proper […]
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