Custom Wire Harnesses

With Kauffman Engineering’s expertise in manufacturing wire harness assemblies, your electronics will be safe in the water, 30,000 feet in the air, or anywhere else.

With our automated preparation abilities, we can minimize the amount of labor needed to build any assembly.

We offer wire harnesses along with various assembly options such as mixed technologies, complex routing, sealed connections, ultrasonic welding, multiple connections, and varying wire lengths.

Simple Wire Harnesses:
<10 circuits

Complex Wire Harnesses:
>200 circuits

26 gauge to 4/0 wire

Wire harnesses can use copper, fiberglass, and plastic including over molding assemblies. The material, sizing, and configuration will depend on the design and application, as well as the type of wire, the amount of wire, and the installation location.

Wire harnesses align all the wires correctly, eliminating electrical interference. Wire harnesses optimize safety and longevity for the application as they protect against harsh conditions. Another advantage is the wire harnesses are easier to install and maintain due to the organization of the wires.

Depending on the application, manufacturing wire harnesses vary in size and length. Wire harnesses are the answer to secure wire connections for any electrical system—designed and manufactured to meet your specific requirements.

  • Reduce electrical malfunctions
  • Enhance equipment performance
  • Decrease the frequency of maintenance and repairs
  • Increase the longevity of your system
  • Amplify the safety of your system

  • Plants certified to ITAR, CSA, UL, AS, TS, and/or ISO standards
  • Automated operations to cut, strip, and terminate 500kcmil to 36 AWG wire
  • Wire/cable Inkjet and heat stamp identification
  • In-house wire, painting, and striping capabilities
  • High volume, low mix through to high mix, low volume optimization, including US and Mexico plant operations
  • Continuity testing

We carry and process connectors and products from all the major terminal and connector manufacturers, such as AMP, Molex, Panduit, Deutsch, Hirose, and Amphenol.

There are three components to build the wire harnesses: wires, connectors, and terminals. This grouping of wires is contained in a protective material to enhance data and energy transmission.