Key Responsibilities and Required Skills for a Harness Designer

🎯 Role Definition

At its core, the Harness Designer is the architect of a product's electrical nervous system. This role is responsible for the end-to-end design, routing, and documentation of complex wiring and cable harnesses that enable power and data to flow throughout a system—be it a vehicle, an aircraft, or a piece of industrial machinery. This professional translates abstract electrical schematics into tangible, manufacturable 3D models and 2D drawings, ensuring every wire, connector, and protective covering is perfectly placed for optimal performance, reliability, and serviceability. They are a critical link between the electrical engineering, mechanical engineering, and manufacturing teams, ensuring seamless integration and functionality.

📈 Career Progression

Typical Career Path

Entry Point From:

Electrical CAD Drafter
Automotive or Avionics Technician
Junior Electrical Engineer

Advancement To:

Senior or Lead Harness Designer
Electrical Project Engineer
Systems Integration Engineer
Engineering Manager

Lateral Moves:

Manufacturing Engineer
Validation & Test Engineer
Systems Engineer

Core Responsibilities

Primary Functions

Execute the intricate 3D routing and packaging of wire harnesses within complex product assemblies, meticulously navigating tight spaces and avoiding mechanical interferences, heat sources, and areas of high vibration.
Develop and release comprehensive 2D harness drawings and assembly documentation, ensuring all specifications, formboard layouts, connector views, and manufacturing details are accurately represented for production teams.
Translate 2D electrical schematics and system diagrams into fully defined 3D harness models, ensuring logical and physical designs are perfectly synchronized.
Create, manage, and meticulously maintain the Bill of Materials (BOM) for each harness assembly, detailing every component from connectors and terminals to wires and convoluted tubing.
Select appropriate electrical components such as connectors, terminals, seals, and wire gauges based on system requirements, environmental factors, and industry standards.
Design and integrate a variety of protective coverings, including braids, conduits, tapes, and heat shields, to safeguard harnesses from abrasion, moisture, and thermal damage.
Collaborate extensively with mechanical engineering teams to define and negotiate harness routing paths, securement points, and clearance requirements within the overall product structure.
Work closely with electrical systems engineers to understand power distribution, signal integrity, and grounding strategies, incorporating these requirements into the physical harness design.
Champion Design for Manufacturability (DFM) and Design for Assembly (DFA) principles to create harnesses that are efficient to build, install, and service.
Actively participate in and present at formal design reviews, effectively communicating design intent, trade-offs, and compliance with project requirements.
Manage and process Engineering Change Requests (ECRs) and Engineering Change Notices (ECNs), ensuring all design updates are properly documented and implemented in PLM systems.
Create and maintain a library of standard harness components within the CAD and PLM environment to promote design reuse and standardization across projects.
Support prototype builds and initial production runs by providing on-site guidance to assembly technicians, troubleshooting fitment issues, and gathering feedback for design improvements.
Investigate and resolve field or manufacturing issues related to harness design, conducting root cause analysis and implementing robust corrective actions.
Ensure all harness designs comply with relevant industry and customer-specific standards, such as SAE, USCAR, and IPC/WHMA-A-620.
Perform detailed analysis of harness bundle diameters, bend radii, and lengths to ensure physical feasibility and prevent strain on wires and connectors.

Secondary Functions

Support the creation of service manuals and installation instructions by providing detailed harness views and technical information.
Collaborate with the procurement team and suppliers to evaluate new components, discuss technical specifications, and ensure component availability.
Participate in DFMEA (Design Failure Mode and Effects Analysis) sessions to proactively identify potential failure modes and incorporate preventative measures into the design.
Mentor junior designers and drafters, providing technical guidance on best practices, CAD tools, and organizational standards.

Required Skills & Competencies

Hard Skills (Technical)

3D CAD Proficiency: Advanced skill in 3D CAD software with specific expertise in electrical routing modules (e.g., CATIA V5/V6 Electrical Harness Discipline, Siemens NX Electrical Routing, SOLIDWORKS Routing).
2D Drafting: Strong ability to create detailed, unambiguous manufacturing drawings, including formboard layouts, that adhere to industry drafting standards.
Schematic Interpretation: The ability to read and interpret complex electrical schematics, wiring diagrams, and system architecture block diagrams.
PLM/PDM Systems: Experience using Product Lifecycle Management (PLM) or Product Data Management (PDM) software (e.g., Teamcenter, ENOVIA, Windchill) for revision control and data management.
Component Knowledge: Deep understanding of wire harness components, including various types of terminals, connectors, seals, wires, and protective coverings.
Industry Standards: Familiarity with key industry standards governing harness design and manufacturing, particularly IPC/WHMA-A-620 and relevant SAE/USCAR specifications.
BOM Management: Meticulous skill in creating and maintaining accurate and complex Bills of Materials.

Soft Skills

Attention to Detail: An exceptional eye for detail is paramount, as small errors in a harness design can lead to significant manufacturing or functional failures.
Problem-Solving: The ability to systematically analyze complex spatial and electrical problems and develop effective, logical solutions.
Cross-Functional Communication: Excellent verbal and written communication skills to effectively collaborate with engineers from different disciplines, as well as with manufacturing and supplier teams.
Spatial Reasoning: Strong 3D visualization and spatial awareness to mentally manipulate objects and envision routing paths in a crowded virtual environment.

Education & Experience

Educational Background

Minimum Education:

Associate's Degree or a Technical Certificate in a relevant discipline.

Preferred Education:

Bachelor of Science (B.S.) degree.

Relevant Fields of Study:

Electrical Engineering / Electrical Engineering Technology
Mechanical Engineering / Mechanical Engineering Technology
Automotive Technology
Industrial Design

Experience Requirements

Typical Experience Range:

3-7 years of progressive experience in a harness or electrical design role.

Preferred:

Experience in high-complexity, regulated industries such as automotive, aerospace, defense, or heavy industrial equipment is highly valued. Direct experience taking a harness design from concept through to full-scale production is a significant asset.