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Electrical Wiring Harness CAD Design Services | ECAD Engineering Solutions

Professional Wire Harness & Cable Assembly Design

Our Electrical CAD Design Capabilities

NESTech engineers, with their rich industry experience and deep understanding of regulatory requirements, provide comprehensive services in the field of electrical engineering. Our team utilizes advanced CAD and electrical design tools to support OEMs and suppliers in developing efficient and compliant wiring systems.

We optimize resources using a shared services model, leveraging software tools like CAD-based electrical systems to deliver value and scalability.

  • Electrical Wiring Harness & Cable Assembly Design
  • Schematic Capture & PCB Layout
  • 2D Wiring Diagrams & 3D Harness Modeling
  • Connector, Terminal & Wire Sizing Selection
  • Formboard (Nailboard) Drawings & Documentation
  • Automotive, Aerospace & Industrial Harness Solutions
  • BOM Generation & Harness Manufacturing Drawings
  • ECAD/MCAD Integration & Collaboration

3D Wiring Harness and Routing Design

3D Wiring Harness Design involves creating a virtual model of electrical wiring systems within a CAD environment. It accurately represents the routing paths, connector locations, cable bundling, and mounting provisions within the physical confines of a product - usually a vehicle or machinery. This approach is widely used in automotive, aerospace, rail, and heavy equipment manufacturing to ensure precise and optimized electrical system integration.

Key Aspects of 3D Harness Routing Design

  • Connector and Terminal Placement: Defining exact spatial positions of connectors and terminals in the vehicle or product environment.
  • Routing Path Definition: Designing optimal cable routing paths that avoid interference, reduce stress points, and conform to design constraints.
  • Bundling and Clamping: Specifying cable bundling strategies, clamps, clips, and brackets to secure harnesses.
  • Integration with Mechanical Layout: Ensuring routing aligns with the mechanical structure, panel cut-outs, and service access zones.
  • Harness Flattening for Manufacturing: Converting the 3D model into a 2D "form board" layout for production.
  • Validation and Simulation: Checking bend radii, slack, and tolerance zones for installation feasibility and durability.

Benefits of 3D Wiring Harness Design

  • Improved Accuracy: Ensures accurate fitment of the harness within complex 3D assemblies, minimizing trial-and-error on the shop floor.
  • Early Issue Detection: Identifies design conflicts (e.g., sharp bends, interferences) before physical prototyping.
  • Reduced Development Time: Automates design processes, reduces rework, and speeds up design iterations.
  • Better Collaboration: Integrates electrical and mechanical teams by sharing a unified 3D environment.
  • Optimized Material Usage: Accurately estimates cable lengths and quantities, reducing material waste.
  • Streamlined Manufacturing: Generates manufacturing drawings and BOMs directly from the 3D model.
  • Supports Variant Management: Easily create harness variations for different product models or customer requirements.

Projects Executed

Wiring Harness Design

  • Preparing wiring diagrams in Pro/Diagram and RSD.
  • Concept routing design tailored for specific divisions and vehicle models.
  • Full harness routing integrated with respective truck platforms.
  • Developing family tables for harness variants based on different dimensions.
  • Creating manufacturing drawings with form board layouts and BOMs.
  • Arrangement drawings to visually demonstrate harness routing.

Top Vehicle Assembly (TVA)

  • Analyzing TVA using skeleton-based assembly and functional divisions via CORE and Agile structures.
  • Component placement and assembly corrections as per division structure.
  • Ensuring compliance of TVA assemblies with standardized data structures.

Services Offered

  • Wiring Harness Design
  • Vehicle Schematic Design
  • Harness 3D Routed Design
  • Flattened Harness Model (Form Board Design)
  • Harness Drawing Creation
  • 2D to 3D Harness Conversion
  • Harness Group Model and Drawing Creation
  • Electrical Component Database Creation
  • Harness Product Build Support

Our Range of Electrical Wiring Harness Services

Harness Design

We create vehicle schematics based on customer specifications. Logical diagrams are developed using standardized electrical symbols, accurately reflecting functional and physical connectivity in the system.

Vehicle Schematic Diagram

3D Routing System

  • Precise placement of connectors and terminals within vehicle 3D CAD environments.
  • Optimized 3D routing paths using CAD cable routing modules.
  • Supports engineers in freezing routing designs and planning real-world harness installation.
  • Identifies connector locations for maintenance and future updates.
3D Harness Routing Design

Flattened Harness Model Creation (Form Board Design)

3D harness models are converted into 2D flattened representations for manufacturing using form board layouts. This step is essential for defining lengths, connector positioning, and splice layout.

Form Board Design

Harness Drawing Creation

We generate all necessary tables for harness manufacturing, such as connector, circuit, splice, terminal, twisted pair, and bundle tables. This parametric generation accelerates 2D drawing creation and improves accuracy.

Harness Drawing Example

Electrical Component Database Creation

  • Centralized and searchable part detail repository.
  • Includes both 2D and 3D views for each component.
  • Database populated using customer input, supplier data, and legacy sources.
  • All data collected and validated before entry for accuracy and accessibility.

Electrical Harness Conversion

Creating 2D harness drawings from physical harnesses, especially when legacy documentation is limited, ensuring consistency with real-world assembly.

Wiring Harness Group Model and Drawing Creation

  • Creating higher-level vehicle harness models including mounting clamps, brackets, clips, and fasteners.
  • Generating drawings that combine the 3D harness model with annotations and connector details.
  • Helps assembly teams visualize installation routes and quickly identify part references.

Case Studies

Flexible Piping

Flexible Piping

Flexible piping design with all suitable connections are designed, further flattened drawing created, Construction Equipment, US Client.

Flexible 3D Routing

Flexible 3D Routing

Piping are flexibly routed through available space with clamps and flattened drawing created for the same

Piping 3D Routing

Piping 3D Routing

3D flexible piping routing done for material handling machine's engine.

3D Harness Routing

3D Harness Routing

3D flexible wiring harness routing done for an engine to an US based client

NESTech Services and Products

Why Choose NESTech as your CAD CAE Partner?

+ Drawings Created
+ Simulations done
+ Team Members
+ Years of Experience
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RICH EXPERIENCE

We bring 25+ years of rich experience to every project, ensuring exceptional results and unparalleled reliability.

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ON-TIME DELIVERY

With meticulous planning, streamlined processes, and a dedicated team, we ensure that every project is completed promptly and efficiently

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EXCELLENT COLLABORATION

We foster a culture of teamwork, communication, and mutual respect, ensuring that every project benefits from the diverse perspectives and expertise of our team members.

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COST EFFECTIVENESS

With a multitude of projects Completed and catering to various industries, we have demonstrated excellent business results at lower cost with our domain expertise.

Some of the Cast-Designer Software Customers