Zuken Introduces Harness Builder 2025

Zuken, a company vested in electrical and electronic digital engineering solutions, unveils the 2025 version of its Harness Builder for E3.series software.  This release introduces new features and enhancements for wiring harness design and manufacturing.

“With this release we are focusing more on the application’s usability by expanding the features to our formboard copilot and adding automation to splice handling with direct integration to Telsonic welding machines.  In response to customer feedback, we’ll continue to add more exports to industry-standard machinery while maintaining strong relationships with our existing partners,” comments Paul Harvell, vice president of Engineering for Zuken USA. 

Copilot Enhancements

Harness Builder 2025 transforms the process of drawing a backbone or segment to a specific length, according to Zuken.  Previously, when utilizing the formboard copilot feature, users could input the desired length of a segment and then quickly add points to the drawing.  As users add points, the copilot displays the added segment length, the total length used, and the remaining distance to achieve the total length. With the 2025 release, the formboard copilot feature introduces a new dialog for entering precise point coordinates, angles, and lengths.

Extended Design Variation Support

Utilizing harness configuration information

E3.series simplifies creating and assigning options and variants in the project. Harness Builder manages the information to generate accurate bills of materials (BOMs) and wire lists based on the active option and variant selection. BOM and wire lists will only include necessary items for the build.

Modular harness design updates

Harness Builder now organizes the BOM outputs into separate tabs for different dash number variants.

Enhanced Wire Length Calculations

The latest release introduces an enhancement based on customer feedback: A new length calculation option allows users to add the length to the front of the connector for precise wire length measurements.

Automation for Manufacturing Documentation

The software can now automatically place missing connector table symbols. 

Advanced Equipment Integration

The latest release has the following integrations:

• Adaptronic Harness Testing Integration: Output designs to the adaptronic wire harness testers.
• Telsonic Welding File Support: Harness Builder outputs to the Telsonic ultrasonic splice welder.
• OMA Braiding Machine Output: Enhance designs with integrated braiding capabilities. The software adds braiding to drawings and provides detailed estimates for manufacturing time, yarn length, weight, and cost.

Enhanced Design Collaboration

This 2025 release, the company has expanded its enterprise resource planning integrations to include a Berrylium interface, enabling connection of the Harness Builder BOM with Berrylium for data synchronization across platforms.

Also, users can broaden design capacity with the new support for PTC Onshape. The option to share E3.series connectivity data facilitates ransitions between CAD platforms. Users can utilize the web-based PTC Onshape to create mechanical designs.

Sources: Press materials received from the company and additional information gleaned from the company’s website.

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