Industrial Wire Harnesses
Custom Industrial Wire Harness Assembly
Custom industrial wire harnesses for PLC control cabinets, servo motors, sensors and ···
Custom Medical Wire Harness Assembly
Medical device harnesses built to ISO 13485 standards
ISO 9001 · IATF 16949 · ISO 13485 · RoHS / REACH
Medical Wire Harnesses
Custom Medical Wire Harness Assembly
Custom medical wire harnesses for patient monitors, diagnostic probes and surgical devices. ISO 13485, biocompatible materials, disinfection resistant, million-cycle flex endurance. 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 Medical Wire Harness?
Custom medical wire harnesses are manufactured in strict compliance with medical industry standards, based on medical device drawings, samples and technical requirements. The process covers cutting, stripping, terminal crimping, connector assembly, branch routing and insulation protection.
We select medical-grade wires, terminals and connectors based on project requirements, integrating power and signal circuits to enable power and signal transmission between PCBs, sensors, probes and control panels in medical devices. Suitable for diagnostic equipment, patient monitors, therapeutic devices, minimally invasive surgical instruments and other medical system integration.
Pain Points We Solve
- Repeated flex fatigue and wire breakageOptimized strain relief at cable exits for probe and handheld handle flexing applications.
- Biocompatibility and disinfection resistanceMedical-grade jacket materials resistant to alcohol and disinfectant wipes, suitable for daily hospital protocols.
- Crimp consistencyStandardized crimp height, cross-section and pull force testing ensure reliable diagnostic signal transmission.
- Tight internal packaging interferenceUpfront DFM review of harness length, branch routing and mounting points prevents chafing inside compact enclosures.
- Batch-to-batch consistencyControlled medical-grade processes with first-article inspection ensure consistent dimensions and electrical performance.
Key Advantages
Fully Custom Development
Custom harness length, branch structure and medical connector types based on your drawings and device specifications.
Medical-Grade Materials
Medical silicone, LSR liquid silicone and biocompatible TPU jackets; non-toxic, non-irritating, no harmful leachables.
Sterilization Compatible
Supports EO, gamma irradiation and autoclave sterilization without deformation, aging or cracking.
Low-Noise Signal Design
Dedicated shielding structure suppresses line-frequency interference for accurate, drift-free data acquisition.
High-Flex Endurance
Designed for repeated bending in surgical tools and handheld diagnostic devices with no core wire breakage.
Cleanroom Production
Produced in controlled environments to prevent dust, particulate contamination and harmful substance leaching.
Main Application Areas
- Patient Monitoring HarnessMulti-parameter monitor, SpO2 and ECG acquisition wiring; stable signal transmission for high-frequency bedside use.
- Handheld Diagnostic Probe HarnessUltrasound probe, therapy handle and endoscope signal harness; flexible, twist-resistant.
- In-Vitro Diagnostic (IVD) Equipment HarnessInternal wiring for biochemical analyzers and immunoassay instruments; low noise and EMI shielded.
- Rehabilitation & Physical Therapy Device HarnessElectrical stimulation and rehabilitation equipment wiring; insulated and flexible.
- Surgical & Minimally Invasive Device HarnessMinimally invasive instrument control wiring; compact and precise, disinfectant-resistant.
Material Selection Guide
Patient contact / wearable
Medical-grade silicone / LSR liquid silicone
Soft, skin-friendly, non-toxic and repeatedly sterilizable.
Reusable device cables
Biocompatible TPU
Body fluid and disinfectant resistant with high abrasion strength.
Imaging / high-frequency signal
FEP / PTFE medical fluoropolymer
High-temperature, corrosion-resistant and high-insulation for sensitive signal paths.
Disposable / cost-sensitive
Medical-grade PVC
Halogen-free and flame-retardant options for single-use device integration.
Technical Specifications
| Parameter | Specification |
|---|---|
| Wire Gauge Range | AWG 8 – AWG 34 (custom available) |
| Conductor | High-flex multi-strand tinned copper, low resistance, oxidation resistant |
| Jacket Materials | Medical silicone, LSR, TPU, FEP / PTFE, halogen-free PVC |
| Operating Temperature | -40°C ~ +150°C (material dependent) |
| Flex Life | Up to 2,000,000+ dynamic bend cycles |
| Shielding | Low-noise composite foil + copper braid shielding |
| Quality System | ISO 13485 / ISO 9001, ISO 10993 biocompatibility materials |
| Lead Time | Samples 5–10 days · Mass production 3–4 weeks |
Customization Process
01
Drawing Submission + Medical DFM Review
Submit 3D drawings, BOM, device application and medical standard requirements. Medical-grade DFM analysis and quotation within 24 hours.
02
Design Confirmation + Prototype
Lock in medical materials, shielding scheme, disinfection-compatible process and structural parameters; deliver validation samples.
03
Performance Testing & Approval
Support customer device-level testing, signal validation and sterilization compatibility testing. Process frozen upon approval.
04
Mass Production Delivery
100% final inspection, full batch traceability, documentation for medical device registration support.
Frequently Asked Questions
Are your medical harnesses ISO 13485 compliant?
Yes. Our medical wire harnesses are produced under an ISO 13485 quality management system, with ISO 9001 as the manufacturing baseline.
Can the harnesses withstand repeated sterilization?
Yes. We select materials compatible with EO, gamma irradiation and autoclave sterilization without deformation, aging or cracking.
Do you provide biocompatibility documentation?
We supply material COA reports and biocompatibility material data to support your medical device registration submission.
Can you build harnesses for handheld probes with high flex cycles?
Yes. Our medical flex designs support up to 2,000,000+ dynamic bend cycles without core wire breakage or open circuits.
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