custom wire harness

In custom wire harness projects, the most frequent client question is:"What wire size should I choose?"This "size" refers to AWG (American Wire Gauge) — a standardized system reflecting conductor diameter, which directly determines a wire’s current-carrying capacity, safety margin, and thermal performance.1. Basic Relationship Between AWG and Conductor SizeLower AWG numbers indicate thicker wires with higher current capacity. Examples:AWG 28 ≈ 0.08 mm² — Ideal for low-current signal linesAWG 20 ≈ 0.52 mm² — Suitable for mid-range powerAWG 14 ≈ 2.07 mm² — For high-power systems2.Current Carrying Capacity Reference (PVC Single Core) AWG Size Conductor Diam. (mm) Max Current (A) Typical Applications 30 0.254 0.228 Signal, LED circuits 26 0.405 0.577 Sensor wires 24 0.511 0.921 USB/Data cables 20 0.812 2.335 Power lines, automotive 16 1.291 5.885 Motors, control cabinets   Critical Notes: Actual current capacity varies significantly with cable length, ambient temperature, insulation material, bundle density, and installation method. Tabulated values are conservative estimates. Always verify with IEC/UL standards or manufacturer datasheets for specific applications.   3. How to Choose the Right AWG for Your Application? Long-distance runs: Require thicker conductors to minimize voltage drop. High-temp/dense layouts: Demand additional safety margins. Consumer electronics: Typically use AWG 28–24. Industrial/vehicle systems: Prefer AWG 20–16.   4. Services from Shenzhen Era WingShing Electronics Co., Ltd. We deliver custom wire harnesses from AWG 30 to AWG 16 with multiple insulation options: PVC | Silicone | PE | TPU UL-certified wires Standard & custom crimping Precision connector assembly   Current values in the image are rounded approximations (1 decimal), while original table data uses higher precision (1-2 decimals); always refer to certification standards or manufacturer specs for actual selection.