Core Service Introduction
We specialize in custom Wire Harness Assembly for complete electromechanical products. It serves as a core part of our end-to-end EMS and box build solutions. Our wire harnesses connect and integrate all electrical components in products, ensuring stable signal transmission, reliable power supply, and long-term mechanical durability in various operating environments. We cater to both simple single-branch harnesses and complex multi-branch, multi-connector wiring systems, fully compliant with IPC-620 and IPC-A-610 workmanship standards, and tailored to specific product design and industry requirements.
Core Capabilities
We offer comprehensive customization options to meet the diverse needs of different electronic products and industries:
Wire Specifications: We process wire gauges ranging from 12AWG to 28AWG, covering single-core, multi-core, shielded, unshielded, and high-temperature resistant wires.
Harness Design: We support custom designs from simple linear harnesses to complex multi-branch, multi-connector assemblies, including wire bundling, routing optimization, and strain relief design. Connectors, terminals, fuses, relays, and heat shrink tubing can be integrated to match product internal layout and installation space.
Material Options
Wire materials include PVC, TPE, XLPE, and silicone. Halogen-free, flame-retardant, and oil-resistant options are available for harsh industrial, automotive, and medical environments.
Connector Compatibility
We work with all mainstream connector brands, including JST, Molex, TE Connectivity, Amphenol, Phoenix Contact, and Yazaki, as well as custom-machined connectors. Precise matching between wires and connectors is ensured, with options for crimped, soldered, or press-fit terminations based on reliability requirements.
Volume Support
We accommodate all production scales, from 1-piece prototype and NPI pilot runs to high-volume mass production. Flexible production lines enable fast changeover for high-mix low-volume orders, ensuring consistent quality across all batches.
Advanced Manufacturing Processes
Our wire harness assembly processes combine automation and manual precision to ensure quality and efficiency:
Automated Crimping and Cutting: We use high-precision automated wire cutting and crimping equipment to ensure consistent wire length, crimp force, and terminal alignment, minimizing human error and ensuring reliable electrical connections.
Precision Soldering: For high-reliability applications, we use automated soldering stations with temperature control to ensure firm, void-free solder joints, avoiding cold soldering or overheating that could damage wires or connectors.
Bundling and Labeling: We use high-quality cable ties, tape, or braided sleeves for wire bundling, ensuring neat routing and protection against abrasion. Custom labeling is available for wire identification, with clear part numbers, wire functions, or assembly dates to facilitate installation and maintenance.
Overmolding and Protection: For harnesses used in harsh environments, we offer overmolding services using thermoplastic materials to encapsulate connectors and wire junctions, enhancing mechanical strength and environmental protection.
Comprehensive Quality Assurance
We implement a strict end-to-end quality control system:
Raw Material Inspection: All wires, connectors, and auxiliary materials undergo incoming quality inspection, verifying material certification, batch traceability, and compliance with RoHS, REACH, and industry-specific standards.
In-Process Quality Control: Each production step is monitored by certified technicians, including wire cutting, crimping, soldering, and bundling. Random pull tests, continuity tests, and visual inspections are conducted to ensure no open circuits, short circuits, or poor terminations.
Final Functional Testing: Every wire harness undergoes 100% functional testing, including continuity testing, insulation resistance testing, and withstand voltage testing, ensuring stable electrical performance and no leakage.
Traceability
We retain complete production and inspection records for every batch, enabling full lifecycle traceability for medical, automotive, and aerospace applications.
Compliance
Our wire harness assembly processes fully comply with ISO9001, IATF16949, and ISO13485 quality management systems. All products meet RoHS and REACH environmental regulations.
Typical Application Fields
Our Wire Harness Assembly services are widely used across automotive electronics, industrial automation, medical devices, telecommunications, new energy, consumer electronics and HVAC equipment.
