Wire harness assembly and processing floor in Shenzhen
CUSTOM WIRING SERVICE

Custom Harness Engineering and Production Process

Send a drawing, sample, connector photo or pinout. We review interfaces, materials, manufacturing feasibility and inspection requirements before defining the sample and production scope.

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Six product families. Specific choices for each project.

Choose the closest family, then define the interfaces, electrical function and installation conditions. A project can combine several families, such as a branched harness with molded connectors and shielded cable.

Custom wire harnesses

Multi-branch harness with several equipment interfaces
Branched harness with a braided protective sleeve

Define a harness around the routing inside your equipment, including power, control and sensor branches. For control panels, robots or instruments, we review the space at each connector, breakout positions and service access, then record the branch lengths, wire identification and protection in the assembly drawing.

What can be customized

  • Point-to-point wiring, pigtails and multi-branch layouts
  • Wire size, color, branch length and connector orientation
  • Braid, sleeves, conduit and abrasion protection
  • Labels, mounting clips and installation kits

Information to confirm

Provide a circuit table and routing drawing, or a reference sample with installation photos.

Specify loads, movement and branch-length datums; current capacity depends on the assembled operating conditions.

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Custom cable assemblies

Double-ended cable with circular M12 connectors
D-Sub cable assembly with several connector branches

Build around the function between two or more interfaces, including signal, data and power connections. Circular connectors, D-Sub, USB, RJ45 and coaxial assemblies each require their own pin map and cable construction. Cable length, shielding, backshells and molded ends are reviewed together for installation and service use. Electrical checks are agreed for the intended use.

What can be customized

  • Connector combinations, keying and straight or angled exits
  • Cable length, conductor arrangement and signal pairs
  • Shield-to-shell termination, drains and grounding paths
  • Backshells, molded ends and strain relief

Information to confirm

Provide both interfaces, pin assignments and the required electrical or communication function.

Define impedance, data rate or power requirements where relevant; connector shape alone does not establish performance.

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Automotive & transportation harnesses

OBD diagnostic cable with three interface branches
Turbo actuator connector lead with protected cable routing

Review OBD, ECU service, J1939 heavy-duty, turbo actuator and vehicle wiring projects against the exact platform and task. Vehicle-side and equipment-side interfaces are checked separately. Pin routes, power paths and shielding are defined with the heat, vibration, fluids and abrasion along the installation route. Functional approval uses the customer’s target equipment.

What can be customized

  • Diagnostic adapters, service leads and branch access points
  • Vehicle connectors, terminals, seals and locking parts
  • Power, communication and actuator circuit routing
  • Heat protection, conduit, braid and mounting points

Information to confirm

Provide the vehicle, year, controller or tool model, plus connector photos and a pin map.

Confirm the target function on the equipment; a passive cable does not convert protocols or guarantee software compatibility.

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Connector & brand-compatible systems

Terminated cable with a sealed rectangular connector
Assorted fine-pitch connector leads and terminal wiring

Use a part number or mating sample to identify the housing, terminal, seal and locking system. For families such as TE, Molex, JST and Deutsch, we review the exact series and sourcing preference, then define the attached cable. Any alternative source needs agreed dimensions and acceptance criteria. Housings with the same pin count can still use different keying and terminal systems.

What can be customized

  • Housing series, pin count, keying and polarization
  • Terminal size, plating and wire-range matching
  • Seals, secondary locks, backshells and accessories
  • Original-part requirements or approved alternative sourcing

Information to confirm

Provide the full part number or clear mating-face and side photos, plus the mating part when available.

Brand-family references identify the selection target. Interchangeability is confirmed for the specific parts and mating pair.

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Specialty cable assemblies & molding

Fine-pitch double-ended wire assembly
Molded Y-branch cable assembly

Review special constructions for compact spaces, fine conductors and protected cable exits. Options include fine-pitch connections, IDC or FFC structures, panel mounts, shield termination and molded strain relief. Material compatibility, tooling and sample checks are assessed together for waterproof or motion-related requirements.

What can be customized

  • Fine-pitch terminations, ribbon and flexible-flat structures
  • Molded strain relief, exit angle and panel geometry
  • Shield continuity, branch joints and protective encapsulation
  • Molding material, tooling and project-specific sample checks

Information to confirm

Provide the installation envelope, cable and connector dimensions, and the target movement or protection conditions.

Agree the complete assembly and test conditions for waterproofing, temperature or flexing; a material rating alone is insufficient.

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Wire, cable & material options

Color-coded flexible conductors
Prepared cable end showing cable layers and conductor termination

Select wire and cable as part of the finished assembly specification. Compare conductor size and stranding, insulation and jacket materials, shielding and pair structure against current, signal and installation needs. Fixed wiring, drag-chain motion, torsion and outdoor exposure require different source specifications and review criteria.

What can be customized

  • Conductor size, stranding, plating and core count
  • Insulation and jacket materials, color and outside diameter
  • Twisted pairs, foil or braid shields and drain wires
  • Temperature, flexing, chemical and marking requirements

Information to confirm

Provide voltage, current, signal type, bend space, ambient conditions and the applicable material specification.

Flame retardance, halogen content and smoke tests are separate requirements; cable selection does not establish finished-equipment approval.

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Four decisions that shape the complete assembly.

Interfaces, circuits, materials and acceptance criteria need to agree with each other. A wire-size change, for example, can also affect the terminal, seal, bend space and crimp setup.

Mating connector housings with terminals and wire exits

The complete mating interface

Confirm the connector series, pin count, keying and orientation, then match terminals, wire range, seals and secondary locks. Include the mating part and the space needed for assembly and removal.

Review output: connector and terminal list with orientation details.

Complete sample harness showing branch positions and interfaces

Circuit paths and dimensional datums

Record pin-to-pin wiring, polarity, signal pairs and shield connections. Define how each length is measured, where branches separate and which connector face sets the orientation.

Review output: pin table and dimensioned assembly drawing.

Multi-core cable with a prepared jacket transition and exposed conductors

Materials matched to the operating conditions

Review load, voltage drop, signal integrity, temperature, motion and fluid exposure together. Select wire, shield, jacket, sleeves and strain relief with the relevant source specifications and test conditions.

Review output: material BOM and the conditions to verify on the sample.

Continuity test equipment connected to an assembled cable

Identification and inspection criteria

Agree wire numbers, labels, barcodes, packaging and drawing revisions. Define visual, dimensional and continuity checks, plus any additional electrical or functional tests required for the project.

Review output: identification rules and an inspection checklist.

From the first requirement to the next order.

Each stage has a customer input and a factory output. Approved drawings, samples and inspection requirements provide the reference for production; changes return to review before they enter a later batch.

  1. Requirement review

    Review the equipment task, interfaces, installation conditions and quantity. List the missing details that affect selection or quotation.

    You provide
    Drawing, sample or connector photos with the equipment task and quantity.
    We prepare
    Project scope and a list of questions to resolve.

  2. Drawing and BOM definition

    Define pin routing, dimensions, materials and inspection items. Review sourcing, tooling and manufacturing steps for the proposed structure.

    You provide
    Confirmed pinout, dimensional datums and material or substitution requirements.
    We prepare
    Drawing/BOM revision and the agreed quotation and sample scope.

  3. Sample build and checks

    Build to the agreed definition. Check dimensions, orientation, identification and continuity; record other tests included in the sample scope.

    You provide
    Approval of the sample definition, quantity and agreed checks.
    We prepare
    Samples and the inspection records agreed for review.

  4. Customer sample approval

    Verify fit and function on the target equipment. Resolve feedback and record changes before the production configuration is released.

    You provide
    Installation and functional feedback, followed by sample approval.
    We prepare
    Approved sample reference and a released drawing/BOM revision.

  5. Production and inspection

    Prepare materials and carry out cutting, stripping, termination and assembly to the released requirements. Inspect the batch against the agreed criteria.

    You provide
    Order quantity and release confirmation against the approved revision.
    We prepare
    Inspected assemblies with batch identification and agreed records.

  6. Delivery and repeat orders

    Pack and label the assemblies as agreed. Retain the approved configuration for repeat orders, and review material or design changes before the next build.

    You provide
    Shipping and packaging details, or the prior order revision for a repeat build.
    We prepare
    Labeled shipment and the configuration reference for the next order.
Automated wire-processing equipment on the production floor
Prepared color-coded conductors at an assembly workstation
Cable continuity inspection with test equipment

Sample approval before production release

Confirm fit, pin assignment and the checks agreed for your equipment. A change to the interface, wire or routing is recorded in the drawing or BOM revision before release.

Send the information you already have.

A complete drawing is helpful, but a sample or clear interface photos can also start the review. Include the equipment task and quantity so we can identify missing details and define the quotation scope.

Reference files

Assembly drawing, BOM, pin table, sample or clear connector photos.

Interface and function

Connector and mating parts, equipment model, power and signal requirements.

Dimensions and installation

Length datums, branches, exit direction, bend space and fixing points.

Environment and materials

Temperature, motion, fluids, shielding and required source specifications.

Quantity and timing

Sample quantity, first batch, expected repeat demand and target timing.

Acceptance and packaging

Inspection items, identification, documentation and packaging instructions.

Material availability, tooling, sample quantity, inspection scope and the production schedule are reviewed for the project.

Before sampling begins.

Can a project start without a complete drawing?

Yes. A sample, clear connector photos and a description of the equipment can start the review. Pin assignments, dimensions and material requirements still need to be confirmed before the sample definition is released. Photos alone may not identify terminals, seals or internal wiring.

Can I specify original connectors or an alternative source?

State the full part number and whether an alternative source is acceptable. We review the housing, terminal, seal and mating pair as a system. An alternative is included only within the agreed scope and after the required dimensional, mating or electrical checks.

Which tests are included for a custom assembly?

The project defines the inspection scope. Dimensions, appearance, identification and pin-to-pin continuity are reviewed against the approved requirements. Insulation resistance, withstand voltage, pull force, ingress protection, signal or functional testing require specified methods, limits and sample conditions before quotation and release.

How are repeat orders and changes handled?

Use the prior drawing/BOM revision and approved sample reference when placing a repeat order. A change to connectors, wire, dimensions, routing or inspection criteria is reviewed and recorded in the revision before production. Material availability and the production schedule are checked again for each order.

GET A QUOTE

Ready to Build Your Harness?

Send a drawing, sample, connector photos or equipment description and quantity. We review interfaces, materials and inspection requirements before confirming a quote and schedule.

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Custom Wire Harness Manufacturing in China

Custom wire harness manufacturing from our China factory, with OEM/ODM project support.

Start with the information you have

A sample, clear connector photos or a description of the equipment and required quantity is enough to start a review.

Information for an accurate quotation

When available, include drawings and BOM, connector and mating part numbers, pinout, wire length and gauge, branch layout, quantity and required tests. Materials, inspection scope and delivery are confirmed for each project.

Send a harness requirement