Wire Harness Design Calculator

Professional engineering tools for custom wire harness design. Calculate AWG size, voltage drop, current capacity, harness cost and connector selection. Designed for industrial equipment, EV, robotics and automation applications.

AWG & Voltage Drop Calculator

Working Current (Amps)

One-way Cable Length (Meters)

System Voltage (V)

Wire Size & Ampacity Calculator

Working Current (A)

Ambient Temperature (℃)

Number of bundled wires

Harness Cost Estimator

Wire Length per Harness (m)

Total length of wire used in one harness, including all circuits.

Connectors per Harness

Annual Volume (pcs)

Wire Cost per Meter ($)

Connector Unit Price ($)

Labor Cost per Harness ($)

Other Parts Cost ($/pcs)

Any other components or processing costs not listed above

Terminal Quantity

Total terminals crimped or installed per harness.

Terminal Unit Price ($)

Number of Branches

More branches usually means higher assembly complexity.

Auxiliary Materials ($/pcs)

Tape, heat shrink, corrugated tube, braided sleeve, clips, etc.

Testing Cost ($/pcs)

Continuity test, electrical test, insulation test, final inspection.

Packaging Cost ($/pcs)

Connector Selector Tool

IP20
Indoor

IP54
Dust & Splash

IP65
Outdoor

IP67
Waterproof

Rated Current (A)

Working Voltage (V)

AWG Reference Table for Copper Wire

AWG	Cross-section (mm²)	Resistance (Ω/km)
10	5.31	3.28
12	3.35	5.21
14	2.08	8.29
16	1.31	13.2
18	0.82	21.4
20	0.518	33.9
22	0.326	53.8
24	0.205	86.0
26	0.128	136

Frequently Asked Questions

What is AWG and how do I choose the right wire size?

AWG (American Wire Gauge) is a standardized system for denoting wire cross-sectional area. The smaller the AWG number, the larger the wire diameter. For most automotive harness applications, 16-18 AWG is suitable for general circuits, while 10-12 AWG is used for high-current paths.

How is voltage drop calculated?

Voltage drop = 2 × Length × Current × Resistance per unit length. For safety, voltage drop should generally not exceed 3-5% of the system voltage.

What factors affect wire ampacity?

Wire ampacity depends on conductor material, insulation type, ambient temperature, and bundling. Higher temperatures and tighter bundling reduce the maximum safe current. Always apply a 20% safety margin.

How do I select the right connector?

Connector selection depends on rated current, working voltage, environmental conditions, and required IP grade. For outdoor or wet environments, choose at least IP65 rated connectors.

How is harness cost estimated?

Harness cost is determined by wire length and gauge, connector type and quantity, assembly complexity, and annual volume. Higher volumes reduce per-unit cost through amortized tooling.

Need Custom Wire Harness?

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