7 Points to Know About Wire Gauge for Wire Harness Manufacturing

Proper measuring standards are critical for custom wire harness manufacturing. If you are unsure 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 everything.

Wire gauge for thickness measurement

Wire gauge for thickness measurement

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1. What are the Measuring Standards for Wires?

Every wire harness manufacturing order comes with tons of information and requirements. Most manufacturing companies tend to ignore some points, and measuring standards 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 means.

An engineer working on the measurements of the wires

An engineer working on the measurements of the wires

If 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, you will get a high chance that you will get AAWG requirement sets. American clients and manufacturing industries use AWG for measurements. The same measuring standard goes for single wire and harness measurements in the United States of America.

The diameter of the electrical wire is the base of AWG. The basic principle of the American wire gauge is slightly different from typical measurements. In everyday life, the more extensive sizes mean the larger object. Well, this is not how the 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 a small wire gauge.

3. British Imperial Standards Wire Gauge

Having a legalized measuring standard is vital for industries and clients, and 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, and 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, what are the differences between them the measurements in metric size? The sizes of the wires rounded off to the total numbers in SWG. On the other hand, the American wire gauge standard does not follow this approach to measure the cables. In terms of accuracy and precision, the 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.

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4. Wire Harness Manufacturing Difference Between AWG and SWG

There are significant differences between these two measuring standards. American wire gauge calculates the size of the wire harnesses in inches. On the other hand, SWG uses millimeters to estimate its size. These two different systems change everything regarding these two standards. You can compare the changes in both standards’ standards’ size charts due to a slight change in the measuring systems. The AWG is more accurate, so at CLOOM Tech, we offer both measuring means. 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. If 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 conferences, there are some similarities. The basic principle of measurement is the same for both standards: 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 bar instead of others.

The worker is packing a wiring harnesses

The worker is packing 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 selecting the correct wire measuring standard, then here are some tips for you. The choice of wire gauge directly impacts your project, so do your homework about these standards.

  • Type of project

The nature of the project is the most critical factor determining the selection of the correct measuring standard. Are you working with robotic wire harnesses or industrial projects? For every project, different wire harnesses are 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, and many other attributes influence the measuring standard’s choice.

  • Space required for wiring

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

  • Calculation of wire gauge

It would help if you remembered that the gauge’s numerical value would decrease accordingly with the increasing physical width of the wire. In simple words, the increase in wire size will lead to a decrease in the gauge’s gauge’s numerical value.

  • Use of large and small gauge

As different gauge sizes are available, the small and large ‘applicationsgauges’ applications are also other. Uses of smaller gauges include electrical lines, heavy-duty machinery, industries, and home and office wiring also uses small meters. Meanwhile, services 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, and many other attributes also define the suitable wire gauge standard. The application of the wire, amperage requirement, and the’s nature of the projects nature also determine the correct 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 harness manufacturers as per the project specifications. The use of custom products will enable businesses and project teams to scale their products better.

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. If you don’t get the proper measures, 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 compelling designs as per the project specifications. CLOOM Tech offers personalized measuring standards for wire harness manufacturing regardless of which measuring standards you want to use. So, let us collaborate for the betterment and growth of your business.


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