That is why many OEMs are shifting toward integrated cable and harness suppliers that can support both component supply and complete assembly manufacturing under one roof.

Instead of sourcing bulk wire from one vendor, cable assemblies from another, and harness manufacturing from a third-party integrator, OEMs increasingly prefer suppliers capable of supporting the full lifecycle of custom cable and harness production.

At Galaxy Wire & Cable, this integrated approach supports customers across industries including aerospace, defense, robotics, transportation, industrial automation, medical technology, and instrumentation. From custom wire and cable design to complete assemblies and harness manufacturing, integrated support helps simplify procurement, improve communication, and reduce operational complexity.

The Growing Complexity of OEM Supply Chains

OEMs today face increasing pressure to:

• Accelerate product development
• Reduce lead times
• Improve quality control
• Simplify procurement
• Control costs
• Reduce downtime
• Maintain supply chain stability

At the same time, products themselves are becoming more sophisticated.

Modern systems often require:

• Hybrid power/data cables
• Shielded signal assemblies
• High-flex robotic harnesses
• Ruggedized industrial interconnects
• Mil-Spec cable systems
• RF/coaxial assemblies
• Environmental sealing
• Compact routing architectures

Managing separate vendors for each of these requirements can create unnecessary complexity throughout the product lifecycle.

What Is an Integrated Cable + Harness Supplier?

An integrated supplier supports multiple stages of cable and harness development within a single organization.

Capabilities may include:

• Custom wire and cable design
• Standard wire and cable supply
• Cable assembly manufacturing
• Wire harness manufacturing
• RF/coaxial assemblies
• Overmolding
• Prototype support
• Engineering collaboration
• Production scaling
• Material selection assistance

Instead of coordinating multiple outside vendors, OEMs work with one partner capable of supporting the entire cable infrastructure.

Galaxy supports customers with custom wire and cable solutions, assemblies and harnesses, RF/coaxial assemblies, overmolded cable assemblies, and standard wire and cable products for a wide range of industries and applications.

How Integrated Suppliers Reduce Vendor Management Complexity

1. Fewer Vendors to Manage

One of the most obvious advantages is reducing the total number of suppliers involved in a project.

Without integration, OEMs may need separate vendors for:

• Bulk cable
• Connectors
• Harness assembly
• Shielding solutions
• RF assemblies
• Overmolding
• Prototype development

Each vendor relationship introduces:

• Additional communication
• Separate quality systems
• Multiple lead times
• Independent documentation
• Procurement overhead
• Logistics coordination

Consolidating these functions with one supplier simplifies purchasing, project management, and ongoing support.

2. Faster Engineering Collaboration

Engineering communication often becomes fragmented when multiple suppliers are involved.

For example:

• One supplier may recommend a cable construction
• Another may identify connector limitations
• A third-party assembler may discover manufacturability issues later in production

These disconnects can delay projects and increase redesign costs.

Integrated suppliers help eliminate these gaps because engineering, manufacturing, and assembly teams work together internally.

This allows for:

• Faster design revisions
• Better manufacturability feedback
• Improved compatibility between components
• Reduced design conflicts
• Streamlined prototyping

Galaxy regularly works with customers during the earliest stages of cable and harness development through production and beyond.

3. Improved Quality Control

When multiple vendors contribute to a cable assembly, quality accountability can become unclear.

If failures occur, OEMs may struggle to determine whether the issue originated from:

• Cable construction
• Connector compatibility
• Assembly workmanship
• Shield termination
• Material selection
• Environmental exposure

Integrated suppliers help improve quality consistency because more of the manufacturing process is controlled within one system.

This often leads to:

• Better traceability
• More consistent workmanship
• Simplified quality documentation
• Faster corrective actions
• Improved process control

For industries such as aerospace, military, medical, and industrial automation, quality consistency is especially important.

Galaxy supports these industries with ISO-certified quality systems and engineering-driven manufacturing capabilities.

4. Simplified Procurement & Logistics

Managing separate suppliers also creates logistical challenges.

OEM procurement teams must coordinate:

• Purchase orders
• Delivery schedules
• Inventory management
• Shipping timelines
• Supplier communication
• Receiving inspections

Integrated sourcing simplifies many of these processes by reducing the number of independent supply chain variables.

Benefits may include:

• Fewer purchase orders
• Simplified inventory planning
• Reduced freight coordination
• Consolidated deliveries
• Improved scheduling visibility

For OEMs operating lean manufacturing environments, these efficiencies can significantly reduce administrative burden.

5. Better Prototype-to-Production Transitions

Many OEMs encounter problems when transitioning from prototype development to full production.

Prototype vendors may not support scalable manufacturing, while production suppliers may not fully understand the original engineering intent.

Integrated suppliers help bridge this gap because they can support:

• Low-volume prototyping
• Engineering revisions
• Pilot production
• Full-scale manufacturing

Galaxy’s low minimum order capabilities are especially valuable for OEMs developing prototypes, pilot builds, and specialized production runs.

6. Faster Response During Supply Chain Disruptions

Modern supply chains remain vulnerable to:

• Material shortages
• Long lead times
• Transportation disruptions
• Raw material volatility
• Global sourcing instability

Integrated suppliers often provide greater flexibility because engineering and manufacturing teams can collaborate quickly on alternative solutions.

This may involve:

• Material substitutions
• Alternate constructions
• Design modifications
• Component standardization
• Production adjustments

Galaxy’s engineering-focused approach has helped customers navigate supply chain disruptions by identifying alternative cable and material solutions when standard sourcing becomes difficult.

Why OEMs in High-Spec Industries Prefer Integration

Industries with demanding performance requirements often benefit the most from integrated cable and harness partnerships.

Aerospace & Defense

These industries require:

• Mil-Spec compliance
• ITAR considerations
• Ruggedized assemblies
• Strict quality control
• Complex shielding systems

Integrated support helps simplify compliance and improve project coordination.

Robotics & Industrial Automation

Automation systems frequently require:

• High-flex cable systems
• Hybrid composite cables
• Compact harness routing
• EMI protection
• Continuous engineering updates

Integrated suppliers can better support evolving system requirements.

Medical Technology

Medical systems often involve:

• Miniaturization
• Biocompatibility
• Sterilization compatibility
• Tight quality requirements
• Precise signal integrity

Integrated engineering collaboration helps reduce design risks.

Transportation & Rail

Transportation systems require:

• Vibration resistance
• Long lifecycle durability
• Environmental protection
• Reliable maintenance support
• Complex communication infrastructure

Integrated manufacturing improves consistency and serviceability.

The Role of Customization

One major advantage of integrated suppliers is the ability to tailor solutions around the OEM’s specific application requirements.

Customization may involve:

• Specialized shielding
• Hybrid cable constructions
• Overmolded assemblies
• High-flex designs
• Environmental sealing
• Unique conductor materials
• Specialized jacket compounds
• Custom harness routing

Galaxy supports a broad range of conductor, insulation, shielding, and jacket material options for custom wire and cable applications.

Common Challenges with Fragmented Supply Chains

OEMs relying on multiple disconnected vendors often encounter recurring issues such as:

Communication Delays

Information may move slowly between suppliers, engineers, and procurement teams.

Compatibility Problems

Connectors, cables, and assemblies may not integrate cleanly.

Longer Lead Times

Coordinating multiple vendors often slows production schedules.

Higher Administrative Burden

Managing multiple supplier relationships increases procurement complexity.

Difficult Troubleshooting

Failure analysis becomes more difficult when responsibilities are spread across vendors.

The Future of OEM Cable & Harness Supply Chains

As systems become more connected and technically sophisticated, integrated supplier partnerships will likely become even more valuable.

Emerging trends include:

• Increased automation
• Hybrid power/data systems
• Higher-speed communication
• Compact electronic packaging
• Supply chain localization
• Faster product development cycles
• Greater customization requirements

OEMs increasingly need suppliers capable of acting as engineering partners—not simply component vendors.

Final Thoughts

Integrated cable and harness suppliers help OEMs simplify vendor management by reducing supply chain complexity, improving engineering collaboration, streamlining procurement, and supporting long-term product reliability.

As products become more advanced and development timelines become more demanding, the ability to work with a single supplier across multiple stages of cable and harness production can create significant operational advantages.

Galaxy Wire & Cable supports OEMs with custom wire and cable design, assemblies and harnesses, RF/coaxial assemblies, overmolded cable assemblies, standard wire and cable products, and engineering-driven manufacturing support for demanding industrial applications. Whether the project involves aerospace systems, robotics, transportation infrastructure, medical devices, or industrial automation, integrated cable and harness support can help simplify operations while improving long-term reliability and efficiency.

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• Cable Assemblies: A cable assembly is a multi-conductor cable that has been cut to a specific length and terminated on one or both ends. It can range from a single wire with connectors on either end to complex multi-conductor cables terminated with various connectors. Cable assemblies are designed to provide a more robust and protected solution for electrical connections, often used in environments where durability and protection from external factors are critical.
• Wire Harnesses: A wire harness, also known as an electronic wire harness or wiring harness, consists of multiple single conductor wires routed and combined in a specific pattern or arrangement. It is primarily used to provide power, signal, or both to a finished product. Wire harnesses are generally less robust than cable assemblies and are used in applications where the environment is less demanding.

Some key differences are:

• Complexity: Wire harnesses can be more complex. They can require more components and a higher level of organization than cable assemblies.
• Application: Wire harnesses are often used for applications with a large number of connections (e.g., automotive, machinery). Cable assemblies on the other hand typically have less connections and involve fewer components.
• Construction: A wire harness can be organized and held together with various types of heat shrink tubing, flexible sleeving, wire ties and other wire management products, whereas a cable assembly could be a single cable or multiple cables and connectors.

As technology continues to advance, wire harnesses and cable assemblies will only become more important, evolving to meet the needs of increasingly complex systems. For manufacturers, choosing the right wire harness or cable assembly is essential to optimizing performance, reducing costs, and ensuring that their products continue to meet the highest standards of quality.

– John Zangara, Galaxy’s VP of Manufacturing

Contact Galaxy to for wire harnesses or cable assemblies manufactured to specification.

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In today’s world, almost every area of technology relies on a complex series of electrical connections. These connections are made by cable assemblies and wire harnesses, which ensure the functionality, safety and reliability of electronic devices and equipment.

Galaxy manufactures assemblies and harnesses for a vast number of end products in industries such as transportation, sensors, OEMs, aerospace, military and medical, among others. As technology continues to grow, the use of wire harnesses and cable assemblies will become vital. Galaxy is the right partner for original equipment manufacturers (OEMs) that need wire harnesses and cable assemblies in their products.

View the online press release for additional details.

Contact Galaxy to assist with current and future requirements. Galaxy strives to exceed customers’ expectations in every area from pricing to quality to delivery, as is evident in this video.

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Recently, Galaxy received an inquiry from an OEM (Original Equipment Manufacturer) looking for a large volume of prepped wire leads. The customer was using 18AWG wire in eight different colors, all cut to a certain length. The wires all had to be stripped and tinned on both ends. This OEM had been working with a different supplier for years. However, pricing had increased recently, and lead times had quadrupled since early 2020. Galaxy was able to turn a quote around in 24 hours with competitive pricing and a lead time that worked for their schedule. Samples were quickly shipped, and production quantities were produced within 3 weeks of receiving the order, allowing the OEM to keep their production line up and running at an important time for their business.

As lead times become increasingly important, utilizing Galaxy as a resource to provide wire leads is a great way to cut down on production time. Please contact Galaxy for assistance with wire lead manufacturing.

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An existing Galaxy customer has seen explosive growth of their products over the past 18 months, coinciding with the COVID-19 pandemic. Galaxy has always been able to support this customer’s needs, but as supply chains around the world have become stressed, acquiring the necessary raw materials to manufacture the end product became extremely challenging. Lead times of the raw materials were extended from weeks to months.

Fearing that shortages in the supply chain threatened to shut down one of their entire factories, the customer and Galaxy collaborated to pivot and avoid disaster for the customer. Galaxy was able to use their expertise to come up with a solution for an alternate part that was more readily available. Even better, the pricing was not affected. In the end, the long lead time was negated, and Galaxy was able to keep supplying the parts with little effect on the customer’s end production.

Galaxy has strong supply chain expertise and can often work with customers to find solutions to such problems. Please contact Galaxy for assistance with challenging wire, cable, or assembly problems.

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An overmolded cable assembly, also commonly called an injection molded or molded assembly, is a cable assembly that has one or multiple ends molded to create a hermetically sealed connector or plug. Molding a cable assembly is often done to help improve the performance and durability of the assembly. An overmolded cable assembly will be more reliable in a rugged and harsh environment and protects all the wire terminations inside the connector. Traditionally a cable assembly is made using a mechanical backshell that has to be assembled. Aside from the increased cost of the physical backshell itself, there can be an increase in build time to manufacture the cable assembly with the mechanical connector; this also increases the final cost of the assembly. Therefore, the option of overmolding is attractive from a cost savings standpoint while at the same time increasing functionality, reliability, and quality.

The advantage of having in-house overmolding is that Galaxy is now vertically integrated and can control the entire cable assembly process to ensure that the quality of the finished product meets Galaxy’s high standards.

Contact Galaxy for Overmolded Cable Assemblies
Please contact Galaxy to learn more about its expanded overmolding/injection molding/molding capabilities and all of wire or cable needs.

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Cable Assembly Case Study
One example of how we worked with occurred recently where a customer was designing an entirely new product line. This customer manufactures equipment for the law enforcement industry. Their new product line is revolutionizing how video is used to capture and record vital information for law enforcement. Having worked with Galaxy in the past, this customer sought Galaxy’s assistance with the wire and cable requirements needed for this project.

In this case, our customer needed custom cable, and they were also looking for help with the cable connections and cable assemblies for their project. We collaborated with our customer on all of the key details of the project: electrical requirements, environmental requirements, and physical demands that would be put on the product. Upon completion of the entire electrical system that would transmit power, signal and video, Galaxy provided working cable assembly prototypes for testing purposes. As is the case in many product launches, changes were made to improve both performance and reliability. We pride ourselves on our ability to communicate with our customers and this was a key aspect in the entire process.

The customer is now supplying the law enforcement community with a great product and Galaxy played a key role in the product development and launch. These cable assemblies ultimately exceeded customer expectations and allowed their end product to function as it was designed to perform.

Contact Galaxy for Custom Cable Assemblies
If you are considering a new source for cable assemblies, you will find that Galaxy is a trusted partner that will work collaboratively with you to develop and manufacture custom cable assemblies for your specific applications. Contact Galaxy today to get started.

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Galaxy is an active supplier to the autonomous vehicle market, offering the sensor cables, custom cable assemblies and electronic wire harnesses that are needed for driverless cars. In particular, Galaxy is rapidly expanding its core competency in developing wire and cable solutions for the sensor industry.

Whether it’s working with a customer to design a brand-new cable or redesigning an existing cable to function as needed to meet the ever-changing technology, Galaxy’s engineering team has the needed expertise. Galaxy has proven its ability to provide wire or cable to the sensor market that supports electrical, mechanical and durability requirements all while keeping costs under control.

Even if the sensor wire or cable is performing as it should, Galaxy’s engineering staff can investigate to see if there are any opportunities for improvement with regards to either functionality and/or cost. Your expertise lies with your product(s), while ours lies with wire and cable.

For a variety of sensor cable needs, contact an experienced sales engineer at Galaxy Wire & Cable today.

The post Sensor Cables in Driverless Cars / Autonomous Vehicles appeared first on Galaxy Wire & Cable, Inc..

The use of biosensors – sensors that convert a biological response to an electrical signal – has enabled medical professionals to detect and diagnose disease in patients. The use of biosensors is also becoming more prevalent in the fitness world with the ability to monitor one’s heart rate and track a user’s activity level.

The use of sensors in the defense industry has among other things increased the use of Unmanned Aerial Vehicles (UAVs). UAVs utilize sensors in a number of ways from optics to temperature to targeting and tracking objects of interest.

The automobile market is expanding its use of sensors. Sensors are being used to assist in parking, breaking and to warn drivers of the proximity of objects. But, some of the more exciting advances are in the use of sensors in the development of driverless vehicles. At some point in the near future, there will be self driving cars on the road.

Sensors are also widely used in the industrial and manufacturing markets. Sensors allow for more automation in the manufacture process. Sensors also reliably transmit critical information during the manufacturing process such as fluid levels, pressure/force, humidity and temperature.

A vast majority of the sensors used in the industries listed above require specially designed cable to accurately measure the environment and transmit data. Sensor cables are built to transmit electrical, temperature and pressure reading for measurement purposes. Some sensors cables must be able to perform in harsh environments with special jacket and conductor compounds designed to withstand heavy duty use. Galaxy has the expertise to help design sensor cables to specific needs and requirements – contact Galaxy today for assistance.

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(from Nicole Lutz, Galaxy President)

As a supplier of wire and cable products that focuses on custom constructed items, Galaxy gets a lot of requests for quote for both custom and commodity types of wire. Many times we get a wire or cable to quote that has been appropriately spec’d – the correct insulation type for the electrical requirements, the appropriate jacket for the insulation, the correct materials for temperature requirements, etc. Other times a customer doesn’t really know what they need, and we help them all along the way. For those that have an existing specification, we’re happy to provide a quote for a wire or cable with any insulation and jacket material that a customer needs.  However, more often than not, a simple conversation and subsequent questions answered might lead us down a path to realizing that perhaps something can be tweaked to improve functionality, lead time, performance, and of course, price.

At Galaxy, we live in the wire and cable world all day long. Most of our customers don’t; they live in the world in which they design and build their products – and they look to whatever resources they can find online to spec in the wire or cable for a project. Do they get it right the first time? Sure, sometimes they do. However, many of the commodity and commercial materials that are readily available are often not quite right, or may even be overkill. The designers are limited to the information they have at hand – usually a commodity catalog – to put on their requirements list. So if it works, it’s good, right? Wrong. This is where the opportunity to improve begins.

One of Galaxy’s biggest success stories in re-specifying materials happened when an end user needed high temperature hook-up wire harnesses for their OEM product. The engineers there did what many typically do – they looked up a commodity type of wire by temperature rating, selected it, and put it on their drawing. When Galaxy received the large bid package for the wire harnesses, we realized that this Teflon wire with silver-plated copper conductors was a big chunk of the bill of materials (BOM) costs. So we checked back with the customer. High temperature was required, but was 200°C required? Could the product still function at 150°C? As it turned out, it could. So, with a simple switch of the UL style to one that’s not standard, we presented a SIX FIGURE costs savings in the package, all by paying attention to the application, and asking the customer what they really needed for the application.

Some people think the word “custom” equals expensive. It doesn’t have to be expensive. Galaxy and its team are trained to ask the right questions and offer the best solutions. We’ll either confirm you’re getting the right product (at the right price), or get you a better one or a better value. What have you got to lose?

The post How to Choose the Right Wire or Cable to Meet Specifications appeared first on Galaxy Wire & Cable, Inc..