Our mechanical assembly capabilities encompass a wide range of non-electrical assemblies designed for precision performance and long-term durability. Examples include worm gear assemblies for subway car doors, float indicators for aircraft fuel tanks, and buffer assemblies used in production-line movement systems. Each product is engineered and built to deliver reliable operation under demanding conditions. While mechanical assembly is essential to creating functional, high-performance products, it presents its own set of challenges. Accurate alignment and secure fastening of components can be time-intensive and often require specialized tools, fixtures, and controlled processes. The overall quality of the finished assembly depends not only on the precision of individual components but also on the consistency and accuracy of the assembly process itself. Even minor misalignments or insufficient joint strength can lead to premature failure—particularly in high-stress or high-cycle applications.

At Harris Assembly Group, our mechanical assembly operations are driven by an unwavering commitment to precision, durability, and performance excellence. Our experienced technicians adhere to rigorous quality control standards and leverage advanced tooling and custom-designed fixtures to ensure every component is aligned and secured to exact specifications. From prototype development through full-scale production, we prioritize repeatability, structural integrity, and long-term reliability. By combining skilled craftsmanship with engineered process controls, we deliver mechanical assemblies that meet stringent performance requirements and consistently withstand the demands of real-world applications.

We manufacture custom cable and wire harness assemblies for critical, high-performance applications including hybrid bus motors, high-voltage battery systems, flight simulators, forklifts, voting equipment, temperature-control systems for over-the-road trucks, and aviation platforms.

Our capabilities range from single-conductor cables to complex multi-wire harnesses with multiple breakouts and terminations. We routinely perform crimping, soldering, potting, and other specialized operations to meet exact engineering specifications. We work with a wide variety of wire types including SXL, PVC, Nylon, Teflon-jacketed, solid and stranded conductors, multi-conductor, and coaxial cable.

To support large-scale assemblies, we maintain 2,000 square feet of winding board surface area, with boards capable of building harnesses up to 56 feet in length. From prototype to production, we deliver precision-built assemblies with consistent quality and repeatability.

Harris Assembly Group provides comprehensive wire termination solutions supporting a wide variety of production volume and specialized high-force applications. Our blend of semi-automated equipment and extensive manual tooling ensures precision, flexibility, and consistent quality across a wide range of terminal types.

We operate 24 semi-automated terminating machines capable of handling diverse terminals and wire sizes, delivering controlled crimp height, secure wire retention, and dependable electrical performance. With over 400 dedicated hand crimp tools, we quickly adapt to customer-specific requirements — ideal for prototypes, low-volume runs, specialized terminals, and custom harness assemblies.

For heavy-duty applications, our pneumatic and hydraulic crimp tools provide the force required for heavy gauge conductors, battery cables, large lugs, and high-current connections, ensuring structural integrity and long-term reliability.

Production Strengths:

• High-mix / low-to-medium volume flexibility.
• Broad terminal compatibility.
• Rapid changeover capability.
• Consistent, repeatable quality.
• Support for both signal and power applications.

From prototype through production, we deliver dependable termination solutions tailored to your specifications.

Harris Assembly Group utilizes advanced automated equipment to ensure precision wire processing for a wide range of applications. We operate automatic wire strip and cut machines, including equipment from Schleuniger and Artos, now part of the Komax Group. These high-performance industrial systems are designed for accurate cutting, stripping, and advanced inkjet wire marking.

• Precision cutting and stripping for a wide range of wire types.
• Heavy-gauge wire processing up to 1 gauge diameter.
• Integrated inkjet marking systems for clear, durable wire identification.
• Consistent, repeatable processing for production environments.

This advanced equipment allows us to maintain tight tolerances, improve traceability, and deliver reliable performance across both signal and power applications.

Harris Assembly Group is a trusted manufacturer of custom battery cable assemblies for OEMs, supported by decades of experience delivering reliable power interconnect solutions.

Battery cable assemblies supply DC power to machines, vehicles, and battery-powered equipment. Each assembly consists of a battery cable with both ends terminated to connect one or more batteries to an electrical system. Assemblies are available in a wide range of lengths and can be terminated with various lugs, connectors, and protective boots to meet application-specific requirements. Selecting the correct cable size and wire gauge is critical for safe and efficient power transfer. Depending on the application, current requirements may range from micro-amps to several hundred amps. All materials and components are chosen to ensure performance in the intended operating environment.

All custom battery cable assemblies are manufactured in-house and in full compliance with applicable regulatory, environmental, and safety standards. Every component and subassembly is thoroughly inspected before shipment. From customer-designed prototypes and First Article Inspection (FAI) builds to full-scale production with 100% inspection, Harris Assembly Group partners with OEMs at every stage. Contact us today to discuss your battery cable assembly requirements.