Custom Cable and Wire Harness Assembly Manufacturing

Application Scenarios

A cable and wire harness assembly integrates power, signal and communication circuits into a ready-to-install component, replacing on-site single-wire wiring and improving consistency and assembly efficiency. From new-energy vehicle high-voltage distribution and charging equipment connections to medical sensor signal acquisition, a harness assembly bundles, crimps and wraps multiple cable runs around the machine's interface layout into a plug-and-play component. Our custom cable assembly manufacturing serves equipment makers and system integrators, with design and production organized around interface definitions, routing space and operating conditions.

Main Harness Types

• HV harness assembly: a connection assembly for new-energy vehicle high-voltage systems, integrating the junction and branching of high-voltage circuits, with routing and branches customized to the vehicle's high-voltage architecture;
• Charging cable assembly: an assembly harness with connector ends on both sides, carrying charging power and connection signals, bend and pull resistant;
• DC fast-charging gun harness: connects main power terminals and charging communication signals, customized to the gun structure and operating conditions;
• Medical sensor cable: transmits signals between medical device sensors and the main controller, with circuit order, length and shielding customized to the interface and sensing type;
• Hydrogen fuel cell harness: serves the electrical connections between parts inside a hydrogen fuel cell generation system, with sub-bundles customized to the system integration layout.

Customization Process

We start with drawing and specification review to confirm interface definitions, wire types, circuit order, terminals and protective structures, then produce samples for confirmation before mass production, followed by inspection and packaging. Wire length, branches and routing can be adjusted to the machine's wiring space and operating conditions.

Quality and Delivery

Production follows a general quality-control flow: incoming material inspection, in-process checks during crimping and assembly, and final outgoing inspection, with full continuity and wiring checks, to ensure consistency and reliability. For the different requirements of power and signal circuits, wire selection, crimp quality and shielding receive special attention.

Contact Us

For custom cable and wire harness assembly requirements, please share your drawings or sample information and contact us for a quotation and prototyping arrangement.