Industrial Wire Harnesses
Custom Industrial Wire Harness Assembly
Custom industrial wire harnesses for PLC control cabinets, servo motors, sensors and ···
Custom Automotive Wire Harness Assembly
Vehicle-grade harness manufacturing to your drawings and samples
ISO 9001 · IATF 16949 · ISO 13485 · RoHS / REACH
Automotive Wire Harnesses
Custom Automotive Wire Harness Assembly
Custom automotive wire harnesses manufactured to vehicle drawings, samples and IATF 16949 automotive specifications. Vibration-resistant, wide temperature range, 100% final inspection. No MOQ.
- Fully custom built to your drawings, BOM and samples
- 100% electrical inspection on every unit shipped
- Free DFM review and quotation within 24 hours
- NDA available before project quotation
What Is a Custom Automotive Wire Harness?
Custom automotive wire harnesses are manufactured in strict accordance with vehicle drawings, samples and automotive industry specifications, covering cutting, stripping, terminal crimping, connector assembly, branch routing and protective taping. We select automotive-grade wires, terminals and connectors based on project requirements, integrating power and signal circuits to enable reliable power and signal transmission between ECUs, sensors and actuators.
Widely used in passenger vehicles, commercial vehicles and new energy vehicles, our harnesses are engineered for the vibration, temperature and contamination extremes of real vehicle environments.
Pain Points We Solve
- Vibration-induced wire breakageOptimized strain relief at wire exits reduces core strand breakage from continuous road vibration.
- Extreme temperature resistanceAutomotive-grade wire and jackets rated for under-hood high temperatures and under-chassis low temperatures.
- Crimp consistencyControlled crimp height, cross-section and pull force testing eliminates intermittent connection failures.
- Assembly interferenceUpfront DFM review of harness length, branch routing and mounting points prevents interference with surrounding components.
- Batch-to-batch consistencyStandardized automotive-grade processes with first-article inspection ensure consistent dimensions and crimp performance.
Key Advantages
Fully Custom Development
Custom harness length, branch routing and connector types based on your drawings, samples and vehicle specifications.
Automotive-Grade Materials
XLPE cross-linked, PUR and TPE-S automotive cables with flame retardancy, oil resistance, wide temperature range and EMI shielding options.
Standardized Crimping
Pull force and cross-section inspection on all terminal crimps for reliable power and signal transmission.
Comprehensive Protection
Corrugated tubing, braided sleeving, fleece tape, high-temperature tape and heat shrink, with grounded shielding for EMC suppression.
Pre-Formed Harness Organization
Harness bundling and clip points designed per vehicle mounting positions to improve assembly line efficiency.
Full Traceability
Laser marking, batch coding and material traceability supporting full vehicle lifecycle tracking.
Main Application Areas
- New Energy Vehicle Control HarnessBMS battery management system, VCU vehicle control unit and motor sensor control harness; high-voltage resistant, EMI shielded.
- Vehicle Sensor HarnessTemperature, pressure and radar sensor wiring; vibration resistant and oil resistant for chassis and under-hood applications.
- Interior Cabin HarnessCenter console, infotainment, seat and door control wiring; compact routing, flexible and abrasion-resistant.
- Commercial Vehicle & Construction MachineryTruck and construction equipment control wiring; reinforced vibration and salt spray resistance.
- Exterior Lighting & Body HarnessHeadlight, reverse radar and exterior lamp wiring; UV resistant and waterproof for outdoor exposure.
Wire & Cable Material Selection Guide
Interior cabin wiring
PVC / XLPE automotive interior cable
Flexible, easy to route and cost-effective for protected cabin environments.
Under-hood high-temperature wiring
XLPE cross-linked high-temperature cable
Withstands under-hood heat and engine oil exposure.
New energy high-voltage / shielded wiring
High-voltage cross-linked insulation + copper braid shielding
EMI suppression for BMS, motor controller and OBC systems.
Under-chassis exterior wiring
PUR polyurethane cable
Flexible, salt spray resistant and abrasion resistant for harsh chassis conditions.
Technical Specifications
| Parameter | Specification |
|---|---|
| Wire Gauge Range | AWG 8 – AWG 30 (custom available) |
| Crimp Process | Fully automatic with pull-force and cross-section control |
| Operating Temperature | -40°C ~ +125°C (high-temp options up to 200°C) |
| Protection Rating | IP67 / IP68 / IP6K9K (custom rated) |
| Shielding | Foil, copper braid or composite — EMI / EMC suppression |
| Connectors | TE, Yazaki, Aptiv, Deutsch, Molex, JST and other automotive brands |
| Quality System | IATF 16949 / ISO 9001 |
| Lead Time | Samples 3–7 days · Mass production 2–4 weeks |
Customization Process
01
Drawing Submission + DFM Review
Submit 2D/3D harness drawings, samples, BOM list, connector and wire specs. DFM feedback and quotation within 24 hours.
02
Design Confirmation + Prototype
Confirm automotive-grade wire, terminal and connector selection and branch dimensions; build engineering samples.
03
Performance Testing & Approval
Continuity, insulation withstand voltage, terminal pull force and vibration endurance tests. PPAP documentation available.
04
Mass Production Delivery
100% final inspection, full batch traceability. Supports OEM, OTS sample, PPAP small batch and long-term vehicle production.
Frequently Asked Questions
Do you support small batch prototyping for automotive harnesses?
No MOQ requirement. We support R&D samples, small batch pilot runs and full mass production.
Are your harnesses IATF 16949 compliant?
Yes. All production follows IATF 16949 automotive quality system standards; certificates and process reports are available.
Can you make shielded high-voltage harnesses for NEV battery systems?
Yes. We specialize in high-voltage shielded harnesses for BMS, motor controllers and OBC systems with full EMC compliance.
Do you offer customer-supplied material (CSR) processing?
Yes. We support incoming material verification and first-article validation before production.
Need a Custom Solution?
Send us your drawings, samples or specifications — our engineers will reply within 24 hours with a free DFM analysis and accurate quotation. NDA available upon request.
Request a Free Quote →
Why Choose Us
Built for Reliability & Compliance
No more intermittent connections, premature failure or missed delivery deadlines.
100% Final Inspection
Every unit tested for continuity, insulation resistance, withstand voltage, terminal pull force and function. Full inspection reports available with every batch.
Industry Compliance
Manufactured under ISO 9001, IATF 16949 (automotive) and ISO 13485 (medical) quality systems. PPAP, FMEA, COA and full documentation support.
Upfront DFM Review
Free design-for-manufacturing review before production. We flag potential issues with crimping, routing, shielding and assembly to avoid costly rework.
How It Works
4 Steps to Your Custom Solution
Simple and transparent — from your drawing to delivered product.
01
Submit Your Requirements
Upload 2D/3D drawings, BOM list, samples or specifications.
02
DFM & Quoting
Free DFM review and accurate quotation within 24 hours.
03
Prototype & Testing
Engineering samples manufactured and tested for your validation.
04
Approval & Mass Production
Locked process, 100% inspection, batch delivery to your schedule.
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FAQ
Frequently Asked Questions
Do you support small batch prototyping? Is there a MOQ?
No minimum order quantity requirement. We support R&D samples, small batch pilot runs and full mass production — matching your product development cycle and volume production needs.
Can you work from our own drawings and connectors?
Yes. We work from your 2D/3D drawings, BOM lists, pin definitions and physical samples. We also fully support customer-supplied material processing — incoming material verification and first-article validation before production.
What certifications and documentation do you provide?
We provide material COA reports, quality system certificates (ISO 9001 / IATF 16949 / ISO 13485), final inspection reports and batch traceability records. Industry-specific documentation such as PPAP, FMEA and control plans available on request.
What is the typical lead time?
Engineering samples: 3–7 business days depending on complexity. Mass production: 2–4 weeks for standard orders. Rush service available for urgent projects — contact us to discuss your timeline.
Ready to Start Your Custom Project?
Send us your drawings, samples or specifications — our engineers will reply within 24 hours with a free DFM analysis and accurate quotation.
- Free DFM review & quotation
- NDA available before quotation
- No MOQ · Prototype to mass production