Electrical Harness Assembly: Custom Electrical & Electro-Mechanical Assemblies Built to Your Specifications 

When a product depends on reliable electrical connections, the quality of the harness and assembly is critical. A well-designed electrical harness helps simplify production, improve consistency, and ensure components are built to exact specifications. 

At Bridgeways, we provide customer-specific electrical harness assembly, cable assemblies, and electro-mechanical assemblies for prototype, low-rate, and production builds. We work on customer specifications and build-to-print requirements with a focus on quality, consistency, and reliable performance. 

What Is an Electrical Harness Assembly? 

An electrical harness is an organized group of wires, cables, connectors, terminals, and protective materials used to transmit power or signals between components. 

Instead of managing individual wires during production, manufacturers can use a completed harness designed for their application. This improves installation, organization, and consistency across builds. 

Bridgeways provides build-to-print wire harness assemblies, cable assemblies, and multi-branch harnesses tailored to customer needs. 

Customer-Specific Electrical Assemblies 

Every application is different, with unique requirements for wire type, connectors, routing, labeling, and testing. 

Bridgeways builds assemblies to customer specifications, including: 

• Wire cutting, stripping, crimping, and termination 

• Connector assembly and pinning 

• Bundling, breakouts, and lacing 

• Heat shrink, sleeving, braiding, and strain relief 

• Shielded cable termination 

• Build-to-print wire harness and cable assemblies 

• Prototype, low-rate, and production builds 

• Kitting and packaging per customer requirements 

From Wire Preparation to Finished Harness 

Quality begins with proper preparation. Each step—cutting, stripping, crimping, termination, and bundling—contributes to a reliable final product. 

Bridgeways uses Capris 50-100 and Nova 800 Cut and Code Machines (26 AWG to 6 AWG), laser marking capabilities, and pneumatic crimping equipment to support consistent, documented processes. 

Aerospace and Manufacturing Applications 

Bridgeways supports electrical assembly for aerospace and other industries, including: 

• BAC5155: Solder sleeve assembly 

• BAC5157: Cable preparation 

• BAC5162: Connector assembly 

• BAC5169: Coaxial connectors and contacts 

• IPC/WHMA-A-620 trained workforce (Space Addendum) 

We are AS9100 certified, providing quality assurance for demanding applications. 

Electrical and Electro-Mechanical Assembly 

Some products require both electrical and mechanical integration. Bridgeways provides electro-mechanical assembly alongside mechanical capabilities such as hardware installation, riveting, drilling, bonding, and finishing. 

This allows customers to work with one partner across multiple assembly needs and simplify production coordination. 

Quality-Focused Assembly and Testing 

Quality is built into every step of the process. Our capabilities include: 

• Visual inspection 

• Continuity and pin-to-pin testing 

• HiPot testing (Iconix/SCI 290-series) 

• Documented assembly processes 

Prototype to Production Support 

Bridgeways supports prototype, low-rate, and production builds, allowing customers to scale as needs evolve. We are known for responsiveness, flexibility, and collaborative support. 

Why Outsource Electrical Harness Assembly? 

Outsourcing can help manufacturers: 

• Reduce internal labor demands 

• Improve production flexibility 

• Maintain consistent build quality 

• Focus on core engineering and business priorities 

For example, our work with Somatic VR helped save approximately 400 hours of manpower in 2024 and about 120 hours per production run. 

A Manufacturing Partner Focused on Your Needs 

Bridgeways combines electrical and mechanical assembly, kitting, and fulfillment services to support a wide range of manufacturing needs. As a mission-driven organization, we also create meaningful employment opportunities while delivering high-quality manufacturing services. 

Looking for a Reliable Electrical Harness Assembly Partner? 

If you need custom wire harnesses, cable assemblies, or electro-mechanical assemblies, Bridgeways can help. 

Contact us at 425-513-8213 or info@bridgeways.org to request a quote or learn more.