Simple to complex, large to small —
we’ve got you covered.
With over 25 years of serving manufacturers of all sizes covering a broad range of industries, Thermtrol can solve your wiring harness and custom electrical assembly needs.
- Flexible manufacturing facilities with the ability to handle both high production programs and short run orders.
- Quick turn-around time on our USA-based short run lines to fulfill prototype, samples to support program development and production launches.
- Engineering support through all phases of design and engineering.
Introduction to Wire Harnesses
Wire Harness Basics
A wire harness or cable assembly is an assembly of wires or cables that transmits signals or electrical power.
- The wire or cable is frequently bound together with wire ties, lacing, sleeves, tape conduit or a number of other options including a combination of the above.
- A harness provides advantages over loose wires and cables by offering decreased installation time and allows for standardization.
- Wires often have terminals attached which can then be assembled into keyed housings for error proofing and connection to other parts of the final assembly.
- Harness assembly is typically done manually due to the many different processes involved.
- Refer to Thermtrol wire harness design guidelines for more information.
Wire harness design is often overlooked in the product development.
- This can result in incomplete drawings and obstacles in the manufacturing process.
- Early partnership with Thermtrol can help guide the design by avoiding many last minute changes.
- OEM Tooling and material lead times can be very long – advanced planning is important.
Harnessing can be broken down into several areas:
- Leaded wire
- Frequently used in point to point wiring
- Typically made on automated equipment
- Low complexity
- Minimal labor
- Good quality
- Additional savings opportunities for customer with bundling the leads into a harness
Wire Harness or Cable Assembly
- Usually includes terminals and housings along with other components
- This can be made via a mix of manual and automated operations
- Often this has a higher labor content and need for the higher quality controls developed by Thermtrol which includes 100% testing
- Wire Harnesses are made up of individual wires where as Cable Assemblies are made with a multi conductor jacketed cable
Cutting/ Stripping/ Crimping
- A key aspect of a high quality harness is the terminal crimp
- Crimping is a method of attaching a terminal or contact end to an electrical conductor
- Essential to control for maintaining good electrical and mechanical characteristics
- Use of OEM components and tooling contribute to a high quality consistent connection
- Thermtrol goes well beyond simply checking crimp height, width and pull test by use of a full terminal verification which includes a cross section analysis of the crimp
Our capabilites equal your opportunities.
As a leading producer of wire harness and over molded products, we possess the broad capabilities to mold virtually anything and engineer the harness solutions that our customers’ require.
Miniature Injection Molded Parts
Over Molded Tubing
Over Molded Wire Harnesses
Custom Over Molding
Over Molded Housings
Over Molded Strain Reliefs
Insert and Injection Molded Assemblies
Multi-conductor Harness Assemblies
Simple Single Lead Terminations
Ribbon Cable Assemblies
MS/Water Proof Terminations
Sensor and Control Harnesses
Combination Crimp and IDC Connector Harnesses
Complex Multi-connector Large Equipment and Vehicle Harnesses
Data and Signal Harnesses
Ultrasonic Welding Capabilities
Combination Crimp and IDC Connector Harnesses
Complex Multi-connector Large Equipment and Vehicle Harnesses
We take great pride in our world-class manufacturing facilities and products.
Manufacturing Facility, Ho Chi Minh City
Our 100,000 sq. ft. production facility in the heart of Vietnam
Commitment to Quality
A working partnership for exceeding customer expectations.
At Thermtrol, quality is more than a process, it's our culture. We engineer every process with precision and build every assembly with care, ensuring your specifications are not just met, but exceeded.
Our thoughtfully designed Quality Management System (QMS) is certified to the internationally recognized standards of ISO 9001 (since 2000), ISO 14001 (since 2015), and IATF16949 (since 2019), and we follow the Advanced Product Quality Planning (APQP) process to define every step required for success. This ensures proactive risk mitigation and repeatable, documented quality protocols and provides you with a dedicated development team to assist with planning, practicability, prototype development, testing, and the Production Part Approval Process (PAPP)
As a Thermtrol partner, this means you will have a knowledgeable manufacturing resource with proven expertise and advanced capabilities committed to supporting you.
Advanced Testing and Validation.
To support our mission, Thermtrol has invested over $1.5 million in cutting-edge quality testing systems in addition to our advanced knowledge in wire processing, crimp technology and over molding. Equipment includes:
Environmental Chambers to ensure performance and dependability under various simulated environmental conditions.
Dynalab and Cirris Cable Testers to verify electrical connections.
Motorized Pull-Force Monitoring to ensure reliability and harness safety.
Temperature Rise Testing to ensure low resistance of terminal and wire combination.
Press Force Analyzers to ensure structural integrity and assembly precision.
On-floor Cross-Section Crimp Testing to optimize crimping parameters and identify early defects.
In addition, our Push-Click-Pull™ method guarantees terminal seating with 100% verification, using custom-built, Poka-Yoke-equipped fixtures that eliminate guesswork and human error.
Built for Reliability
We don’t rely on end-of-line inspections alone. Our team performs in-line validation and real-time monitoring throughout production—ensuring consistency, compliance, and performance shift after shift. Whether you're building HVAC systems, automotive assemblies, or industrial equipment, you can rely on Thermtrol for proven, repeatable results.
Our commitment to excellence is backed by world-class quality systems incorporating Six Sigma methodology, TVR reports, press analyzers, and a comprehensive BBMX system. These are all supported by cutting-edge technical labs and a quality-driven culture at every level of our organization.
Learn more about our Commitment to Quality
Engineering and Development Assistance
Thermtrol supports all phases of design and engineering of new wire harnesses
and over molded products.
There are three major steps in development
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Step 1Conceptual configuration to determine the relative dimensions needed.
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Step 2Pre-production design proof of the proper form to be used in manufacturing.
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Step 3Manufacturing and pre- production test-runs to support testing and prove manufacturing process prior to full-scale production.
In addition, we offer timely and cost-effective evaluation of your existing or planned custom wire harness assembly and overmolding needs. Thermtrol customers rely on our engineering assistance to redesign components and help them maximize product reliability, simplify installation and streamline their supply chain.
