When designing a part for laser or waterjet cutting minimize “Pierces”. A pierce is where the cutting beam/jet must drill through the material. Each pieces take the same amount of time as cutting a several cm of length. In addition piercing material can damage the surface finish or affect the mechanical properties.

Always attempt to use connectors with “built-in” strain relief.  If not available for your application consider over-molding first and last heat shrink. In addition design an “S” bend into all harness joints to provide strain relief.  The number one failure mode of cable harness is wire to terminal connection. Pull force, vibration and bending all can damage these joints. Worst still these are typical intermittent failures which are extremely hard and expensive to diagnosis.

To prevent “bridging” when routing wires harness on internal bends include an “S” bend.  The “S” bend will allow the harness to route on an internal corner with no “bridging”. In addition the “S” bend will allow for variations in harness length without causing “bridging” or other unintended interference