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5.1 What is Box Build (System Integration)
Box Build, often referred to as System Integration or Final Assembly, is the manufacturing stage ...
4.14 Final Inspection and Traceability
Final inspection is the last line of defense before the product leaves the controlled factory env...
4.13 Final Electrical Validation (CIR/HIPOT)
Visual inspection confirms workmanship, but only electrical validation confirms function. A harne...
4.12 Identification and Labeling
Labeling is the "User Interface" of a wire harness. For the installer, it ensures correct connect...
4.11 Form Board and Routing Design
The Form Board (or Jig Board) is the physical template that transforms a 2D engineering drawing i...
4.10 Soldered and Ultrasonic Terminations
While crimping is the standard for high-volume termination, soldering and ultrasonic welding are ...
4.9 Crimp Quality Assurance
A finished crimp hides its internal quality. To the naked eye, a loose crimp and a perfect gas-ti...
4.8 Crimping Fundamentals
Crimping is the most critical process in wire harness assembly. It is not merely folding metal ar...
4.7 Tooling and Machine Capability
High-speed wire processing machines are the heartbeat of the harness shop, often producing thousa...
4.6 Complex Cable Preparation
Processing complex cables requires a fundamental shift in mindset from simple connectivity to geo...
4.5 Wire Preparation: Single Conductor Processing
Wire preparation is the high-speed automated foundation of the entire harness manufacturing proce...
4.4 Connector Families: The Mechanical Interface
The connector is the only part of the harness designed to be disconnected, making it the weakest ...
4.3 Insulation & Cable Structures: Environmental Armor
If the conductor is the heart of the harness, the insulation and cable structure are its skin and...
4.2 Conductor Materials: The Electrical Core
The conductor is the functional heart of any wire harness. Its selection dictates not only the el...
4.1 Quality Baseline: IPC/WHMA-A-620 Classes
The IPC/WHMA-A-620 standard is the mandatory quality benchmark for the cable and wire harness ind...
3.15 Coating & Potting
Residues left behind in assembly are often invisible, yet they can dictate whether a circuit surv...
3.14 Press-Fit Technology
Press-fit is a mechanical interconnection technology that uses a compliant pin design to create a...
3.13 Depanelization Choices
Depanelization is the final mechanical process that separates individual Printed Circuit Boards (...
3.11 Clean vs No-Clean Decisions
Residues left behind in assembly are often invisible, yet they can dictate whether a circuit surv...
3.10 Data Logging & Repair Tickets (THT/Mixed)
The manual and mixed-technology assembly process — especially THT insertion, wave soldering, and ...