Bundle size calculator
INPUTS
Type
Spec
Size
OD
Count
RESULTS
Bundle CSA:
— mm²
Bundle OD:
— mm
Bundle OD + future-proofing:
— mm
Final OD
—
Important Note
This calculator is provided as a practical engineering aid for preliminary bundle sizing and design support. It has been developed with care to improve speed and consistency during the design process.
All results are indicative only and should be independently reviewed by the user against the relevant wire data, covering data, installation conditions, applicable standards, and project-specific requirements.
EDS Master recommends physical validation, such as prototype or sample verification, before relying on the results for final design release, manufacturing, testing, certification, installation, or any safety-critical, regulated, or validation-sensitive application.
Supplier part numbers, specifications, and brand names are used for identification and reference purposes only. All trademarks remain the property of their respective owners. No affiliation or endorsement is implied.
How to use
1. Select the Default wire spec. This will be used only for newly added standard wires, not for wires already in the list.
2. Click Add wire to add normal single-core wires. You can then change the spec, size, and quantity as needed
3. Click Add MC/TP to add multicores (MC) or twisted-pairs (TP). After selecting the spec, the calculator will identify it as MC or TP automatically.
4. Click Add Coax to add coaxial cables.
5. Adjust the quantity of each row with the + / − buttons or by typing a value directly.
6. Enable Future-proofing when sizing a new harness that may require later changes, such as new vehicle features, optional equipment, or additional electrical content after initial release. For example, 0.20 = +20% additional bundle Cross Sectional Area.
7. Click Calculate to generate the estimated Nominal bundle cross-sectional area, Nominal bundle OD, and a cross-section visual.
8. Click Reset to clear all rows and start again.
Typical harness bundle sizing considerations by industry
Automotive
Common wire families include FLRY and ISO 6722. Typical concerns are tight packaging, branch density and complexity, as well as future-proofing. In addition to standard primary wires, automotive harnesses may also include coaxial cables such as DACAR302 and RTK031, used for infotainment systems, Radio and GPS antennas, and other related communication functions. Where these cables are present, bundle diameter checks help confirm local space claim, branch transitions, and protection selection around more sensitive signal content.
Commercial Vehicles
Harnesses often need to balance packaging, serviceability, protection, and longer routed paths. Bundle sizing is especially useful for space claim and conduit selection. Commercial vehicle harnesses may also contain coaxial cables such as DACAR302 and RTK031, especially for camera systems, ADAS, GPS, telematics, and other communication equipment. Checking bundle size early helps when these signal cables run together with power and standard vehicle wiring through long routes, articulated areas, and protected branches.
Autonomous Vehicles
Autonomous vehicle harnesses often contain many coaxial and automotive Ethernet cables, together with subassemblies using FAKRA, HFM, MATEnet, and H-MTD connections. This makes bundle planning more complex because mixed signal and data branches need careful packaging and separation. These branches need extra attention at bend radius, breakout areas, and connector transitions. Early bundle OD estimation supports routing zones, branch design, and suitable covering selection without overstressing sensitive data cables in the routing.
Off-Highway Equipment
Robust protection systems are often required due to abrasion, weather, fluids, vibration, and long routed runs. In this kind of environment, bundle sizes need to be checked not only for the nominal conductor packing, but also for conduit tube selection and other durable coverings used to protect the harness in harsh conditions. Early bundle sizing helps when reviewing corrugated tube, heavy-duty sleeves, P-clamps, grommets, and when measuring clearances for static condition or around dynamic structures during packaging review.
Heavy Machinery
Large harness sections, harsh environments, and service constraints make bundle growth especially important. Future-proofing should be considered when variant content, optional equipment, or extra electrical functions are expected. Heavy machinery harnesses often combine long routes, large protected bundle sections, and demanding installation conditions where clips, conduit tubes and service loops all matter. A realistic bundle size estimate helps improve routing robustness and protection hardware selection.
Motorsport
Motorsport harnesses often use Spec55 and Spec44 wires in concentrically twisted bundles, with very compact Autosport connectors. Even with small wires, bundle size still matters because it affects the correct selection of Raychem boots, DR-25 coverings, and other shrinkable tubes used. Accurate bundle sizing is especially useful in motorsport harness layouts, where lightweight construction, compact packaging, and reliable sealing must work together without increasing the cost of the harness.
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