Introducing the HPE Cable Bundle Diameter Calculator

As Harness Design Engineers, we regularly need to estimate cable bundle diameters quickly and accurately during harness design and quoting.

While there are various reference methods available, many engineers still rely on spreadsheets or rules of thumb. We’ve now made that process faster and more accessible with our new Cable Bundle Diameter Calculator.

The tool allows you to:

• Combine multiple wire gauges in a single bundle

• Add quantities per wire type

• Include braid and jacket allowances

• Enter custom wire ODs where required

• Instantly calculate estimated bundle diameter

  
  

How It Works

The calculation accounts for interstitial space between wires and provides a realistic engineering estimate.

Wire gauge references are derived from SAE AS81044/12 dimensional data, and lay length considerations follow typical IPC/WHMA-A-620 recommendations (8-16× bundle OD depending on construction).

Why We Built It

Accurate bundle diameter estimation matters for:

• Backshell selection

• Braid selection

• Jacket selection

• Heatshrink boots

• Installation clearances

  
  

This tool is designed to remove guesswork and speed up early-stage design decisions.

You can try it here:👉 www.harnesspro.co.uk/cable-bundle-calculator

As always, this provides an engineering estimate — actual bundle diameters may vary depending on lay length and assembly method.

We’d welcome feedback from anyone using it in design or production environments.