So, you’re in the market for a new custom wire harness, complete with all the bells and whistles. Where do you begin? Choosing the best design options can be intimidating at times. While you may have different pieces of the puzzle, putting them all together to form a functional, reliable wiring solution can be bewildering. Whether you’ve been around electrical engineering for years or are purchasing for the first time, we’ve got your back for all you need to know.
Unlike other wiring solutions, there are no “plug-and-play” options when it comes to wire harness terminals. That’s why it helps to have an expert in your corner, guiding your every step. Our team created this guide to help you along your journey. You’ll learn about the various design elements for wire harness terminals to create a custom wire harness that strikes all the right notes. Here’s your guide to choosing the best design options for wire harness terminals.
Heat Shrink Terminals: Superior Sealing and Protection
Some wire harness terminals need that extra something that protects them against the elements. When you’re working in conditions involving moisture, salt, or steam, heat shrink terminals are your new best friend. This type of terminal forms a watertight seal around the terminal, giving it extra protection from harmful invaders and environmental hazards.
As we all know, water and electricity don’t get along well. When heat is applied to terminals, they shrink around the wiring components, making it nearly impossible for moisture and other pollutants to enter. This is ideal in environments that may be extra challenging for electrical equipment like boats, RVs, outdoor spaces, or any other place that may be exposed to water.
Heat shrink wire harness terminals offer superior sealing against the harshest conditions, giving your equipment an additional layer of protection – and you an extra sense of security. Think about heat-shrinking terminals the way a Navy SEAL might think about choosing between a dry suit and a wet suit: The choice is obvious when even a little water could blow the whole operation. Additionally, heat shrink terminals hold wires in place, helping with proper wire management.
Vinyl Insulated Terminal: Cost-Effective Defense
When you’re building on a budget, you may need to stick to the basics. But that doesn’t mean you should compromise on wire harness defense. That’s where vinyl insulated terminals may be the best option for your project. These wire harness terminals offer a basic level of protection without fancy bells and whistles. Think of them as the “no-frills” terminal options.
Because vinyl insulated terminals are a reliable, budget-friendly option, they are ideal for household wiring and other budget-conscious projects. As an old wiring standby, please note that reliable terminals are well suited for indoor applications, where Mother Nature isn’t welcome. They may not have fancy features or much glamor to their name, but you can always count on them in a pinch.
Of course, in most home wiring projects, a vinyl insulated terminal won’t face a hurricane or major catastrophe. Instead, they’ll fight against mild, “average Joe” attacks. However, when you need a reliable option that won’t bust your budget, a vinyl insulated terminal is a fantastic choice.
Nylon Insulated Terminals: Tough and Durable for Harsh Conditions
Some wiring projects just require more muscle than others. That’s where nylon insulated terminals come into play. These are the bodybuilders of the custom wire harness world, with formidable capabilities and even tougher durability. These guys can take a beating and keep on trucking like it’s a typical Tuesday morning. Better suited for a military compound than a residential wiring setup, nylon insulated terminals for wiring harnesses are capable, rugged, and stout.
If you work in “rough and tumble” environments, like the military, aerospace engineering, or industries operating in harsh conditions, nylon insulated terminals are your best bet. These hardy workhorses tackle challenging environments with ease, never shirking from their heavy load. Naturally, when your industry demands so much from its custom wire harnesses, durability is a non-negotiable design feature. These tough wire harness terminals have the credentials, durability, and tried and true stick-to-it-ness to tackle the most rugged industrial circumstances.
You’ll most likely find nylon insulated terminals in high-heat industrial environments, military applications, and aerospace industries.
Non-Insulated Terminals: Practical, Economical, and Efficient
When you don’t need the extras and prefer to keep things simple, a non-insulated terminal option might suit you just fine. These wire harness terminals are certainly the most economical of the bunch, taking only what they need and nothing more. Think of these as minimalist choices that give a simplistic feel to simple jobs. These types of terminals are well-suited for environments that don’t require extra protection or features.
Despite not including insulation, a non-insulated terminal option can still be a suitable choice when the situation allows. Designing the perfect solution for the application is what our team does best and this route offers a fantastic, base-level wiring solution. You’ll find non-insulated terminals in low risk electrical projects, simple wire harnesses, and basic electrical operations. Of course, while these are not the gallant heroes of the story or the brute force of the wiring world, they still get the job done.
For custom wire harnesses that just need the basics, a non-insulated terminal option may work best. Of course, depending on your equipment, these may not always be viable. Our team can help analyze your unique set-up before finalizing your custom wire harness design.
High-Temp Terminals: They Can Take the Heat
You know what they say about “if you can’t take the heat…” Fortunately, high temperature terminals are explicitly designed to take the heat and keep their cool. These wiring harness terminals are like the firefighters of the terminal world. They’re well insulated from industrial heat, giving them a distinct advantage when things get toasty.
High-temperature wire harness terminals are made with materials that naturally resist scorching heat, like nickel-plated steel. You’ll find high-temperature terminals in everything from the fiery depths of your oven to the engine bay of your car. Other environments will likely include industrial mechanics, heavy-duty applications, and light fixtures.
The right terminal can be the difference between a smooth connection and an electrical meltdown, literally in some cases. That’s why it’s critical to understand your equipment and environment when creating a custom wire harness. With the appropriate terminals, your connection project can tackle anything.
Overmolded Terminals: Customized to Perfection
Overmolded terminals utilize injection molding to provide the perfectly encapsulated junction of wire and connector. Overmolding produces a tremendous number of benefits, including durability, strain relief, and proper cable management, but the greatest benefit overmolded terminals offer is versatility in creating a stout one-of-a-kind connection.
Overmolded terminals are unique, down to the last detail. This level of customization isn’t about flair; it’s a precisely engineered solution designed for the application at hand to ensure the continuity, integrity, polarity, and functionality of the system. When designing something with this degree of accuracy, expertise, and exactness are non-negotiable.
While not every wire harness manufacturer has the capabilities to create solutions like these, our team designs and manufactures each overmolded project we undertake. It helps to have several decades of experience under your belt when designing perfection—which is exactly what we bring to the table. Fortunately, we’ve developed the skills and curated the specialized equipment to create overmolded terminals with meticulous attention to detail and ultra-precision.
Testing is a huge component of our success, and we utilize our Advanced Testing Lab to test each and every component to ensure it meets rigorous standards before being delivered to our clients.
Wire Wisely with Meridian’s Guidance
Whether you’re developing a pioneering concept in electrical engineering or crafting a custom wire harness for a simple wiring project, you want a partner with the skills, expertise, and proven track record at your disposal. That’s where we come in.
Since 1994, we’ve cultivated a team of excellent engineers, precision manufacturers, and diligent developers to design and build custom wire harnesses, custom cable assemblies, and wiring solutions you can count on. We put our team to the test with every project we work on.
When you choose Meridian for your custom wire harness project, you can rest easy knowing you’ve got our expertise in your corner. Every product we develop is something we’re proud to deliver. With a manufacturing warranty, industry-recognized certifications, and our team creating your project, you’ll have a one-of-a-kind custom wire harness before you know it.
We’d love to talk to you about your next project. We’re always just a quick contact away. Start your custom wiring project today!