7 Points to Know About Wire Gauge for Wire Harness Manufacturing

We understand the inherent frustration that comes with choosing the right cable assembly, which is why we take out the entire process of choosing your cable assembly. Instead, we create the cable assembly that you want the way you want it.

Our custom cable assemblies have better wiring and insulation than off-the-shelf cable assemblies. You can choose the connector that you want throughout your cables; you can also choose the material of the wiring itself. We test out wires for the best performance that you can buy, ensuring that the custom cable that you are buying is the best around.


Right measuring standards are critical for the custom wire harness manufacturing. If you are not sure what measuring standard is suitable for your project, don’t go for the hit and trial method. Measuring standard is not something that you can alter after the production of wire harnesses. For accurate and precise wire harness manufacturing, you need to know about this everything.

Wire gauge for thickness measurement
Wire gauge for thickness measurement

1. What are the Measuring Standards for Wires?

Every wire harness manufacturing order comes with tons of information and requirements. Most of the manufacturing companies tend to ignore some points, and measuring standard can be one of those points. AWG and SWG are the recognized standards in the United States and other countries to measure wire gauges. The measuring standards are not universal and can change for different countries. These two standards are most famous in several countries, so manufacturing companies also follow these standards. While ordering bulk production of wire harnesses, don’t forget to discuss the details about measuring standards.

An engineer working on the measurements of the wires
An engineer working on the measurements of the wires

In case you have provided instruction in AWG, and the manufacturer deals with SWG; such a situation can make things critical for both parties. The end product may not meet your project specification due to the difference in measuring standards. The best way to avoid these issues is to discuss the standard measurements before starting the design process.

2. American Wire Gauge

The first measuring standard for wire harness manufacturing is American wire gauge or AWG. It is the American standard for the measurement of wires in wire harnesses. If you are dealing with an American client, there are high chances that you will get requirements in AWG. American clients and manufacturing industries use AWG for measurements. The same measuring standard goes for single wire measurement and wire harness measurements in the United States of America.

The diameter of the electrical wire is the base of AWG. The basic principle of American wire gauge is slightly different from typical measurements. In normal life, the larger measurements mean the larger object. Well, this not how American wire gauge works. This rule is different for not only the AWG but all other gauges too. The physical size of the object is something that matters the most. American wire gauge states that the larger physical size of the wire means small wire gauge.

3. British Imperial Standards Wire Gauge

Having a legalized measuring standard is important for industries and clients. Lack of standard can lead to conflicts and other technical issues later on. Like American wire gauge, the UK also introduced standard measurements in 1884. SWG is the measuring standard in the United Kingdom for wire harness manufacturing. These standards are also known as SWG or British Imperial Standard Wire Gauge.

Assemble wire harness, electrical wire
Assemble wire harness, electrical wire

As SWG and AWG are two different measuring standards, so what are the differences between these two standards? SWG defines all the measurements in metric size. The sizes of the wires rounded off to the full numbers in SWG. On the other hand, the American wire gauge standard does not follow this approach for the measurement of the wires. In terms of accuracy and precision, America wire gauge is way better than SWG. Most of the clients have complaints about the sizes of wires that come from the United Kingdom. AWG is a comparatively better standard for measurements in wire harness manufacturing.

4. Wire Harness Manufacturing Difference Between AWG and SWG

There are major differences between these two measuring standards. American wire gauge calculates the size of the wire harnesses in inches. On the other hand, SWG uses millimetres to calculate its size. These two different systems change everything regarding these two standards. You can compare the changes in the size charts of both standards due to a slight change in the measuring systems. The AWG is more accurate, so at CLOOM Tech, we offer both measuring standards. Our clients are from both regions, so we offer the flexibility of measuring standards.

Both systems have their applications, and no system is less effective. The application of the standards is associated with the geographical locations of both parties. In case you are outsourcing wire harness manufacturing to China or any other Asian country, don’t forget to discuss the measuring standards in the earlier stage.

5.Wire Harness Manufacturing Similarities Between AWG and SWG

Although both measuring standards are different and have a lot of differences, yet there are some similarities too. The basic principle of measurement is the same for both standards, and that is the physical size of the object. Both measuring standards for wire harness manufacturing use a metal measuring plate for measuring wires. But these similarities do not allow the industries of clients to use one standard instead of others.

The worker is packing a wiring harnesses
The worker is packing a wiring harnesses

6. Wire Harness Manufacturing How to Choose the Best Wire Gauge?

Wire harness manufacturing processes can be complicated, and you will need assistance. If you are confused about the selection of the right wire measuring standard, then here are some tips for you. The choice of wire gauge has a direct impact on your project, so do your homework about these standards.

  • Type of project

The nature of the project is the most important factor that determines the selection of the right measuring standard. Are you working with the robotic wire harnesses or industrial project? For every project, different wire harnesses required. Here are some general cases where you will have to use wire harnesses:

• Home wiring
• Robotics
• Computers
• Vehicles
• Appliances

Every project has unique gauge requirements, so one size does not fit all projects. Size, designs, electrical specifications of the project, and many other attributes influence the choice of the measuring standard.

  • Space required for wiring

With different sizes of the wires, you will have to manage different spaces in the appliance or the chassis. For accurate wire harness manufacturing, you should state project requirements. Once the manufacturing team has all the requirements on the table, they can suggest the best gauge. In industrial units, wire harnesses have to carry larger currents so that the size will be larger. In robotic wire harness, a minor amount of current is enough to power the functions of the robots.

  • Calculation of wire gauge

You must remember that with the increasing physical width of the wire, the numerical value of the gauge will decrease accordingly. In simple words, the increase in wire size will lead to a decrease in the numerical value of the gauge.

  • Use of large and small gauge

As there are different gauge sizes available, the applications of the small and large gauges are also different. Uses of smaller gauges include electrical lines, heavy-duty machinery, and industries. Home and office wiring also use the small gauges. Meanwhile, uses of larger gauges include computers, robotics, radios, GPS, and phones.

  • Amperage requirements

How much amperage do you need for your project? It is an important question that defines the gauge standard. There are many other attributes too that define the suitable wire gauge standard. The application of the wire, amperage requirement and the nature of the project also defines the right measuring gauge for wire harness manufacturing.

7.Custom Wire Harness Manufacturing and Custom Wire Gauge

In case of standards, wire gauge measurements don’t meet your project specifications; you can try custom wire harnesses. Custom wire harnesses allow the industries to have their unique wire harnesses manufactures as per the project specifications. The use of custom products allows businesses and project teams to scale their products in a better way.

Market wire harnesses have specific gauge measurements, so those measurements may not be according to your project specifications. While ordering custom wire harness manufacturing, make sure that your chosen supplier has experienced both measuring standards. In case you don’t get the right standards, what is the point of investing in custom services?


If you are also looking for accurate wire harness manufacturing for your project or industry, CLOOM Tech can offer the best services. We have state of the art design instruments to come up with unique and effective designs as per the project specifications. No matter which measuring standards you want to use, CLOOM Tech offers personalized measuring standards for wire harness manufacturing. So, let us collaborate for the betterment and growth of your business.

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