Wire Harness Manufacturing Excellence
Custom wire harness design and manufacturing for automotive, medical, and industrial applications. ISO 9001 certified with global production capacity.
What is Wire Harness Manufacturing?
Wire harness manufacturing is the process of organizing and bundling multiple wires, cables, and terminals into a single assembly. These assemblies provide organized electrical connections in complex systems, reducing installation time, improving reliability, and simplifying maintenance across various industries.
Wire harness, cable harness, and wiring loom are often used interchangeably. Cable harnesses can combine multi-conductor cables with individual wires for power and signal routing. A wiring loom groups conductors, connectors, splices, labels, and protective materials into an assembly ready for installation, with controlled branch locations and service access.
Custom Engineering
Our engineering team develops harnesses to your electrical, mechanical, and environmental requirements, with design for manufacturability (DFM) reviews, 2D/3D CAD, connector selection, and bill of materials optimisation. Engineering support is complimentary on projects that proceed to production.
High Volume Production
Automated and semi-automated production lines support high-volume manufacturing, with real-time crimp force monitoring on every automated crimping cycle. We also support low-volume, high-mix builds.
Automotive Grade
ISO 9001:2015 quality management and IATF 16949:2016 automotive certification support controlled manufacturing. ISO 13485:2016 applies to medical wire harness production, with IPC/WHMA-A-620 Class 2 or Class 3 workmanship to suit the application.
Prototype to Production
No minimum order quantity: start with a single prototype, confirm the first article, and progress through pilot builds to repeat production. The approved sample, BOM, branch lengths, labels, and test criteria form the controlled build package for later orders.
Global Manufacturing
Manufacturing facilities in Asia with Melbourne-based engineering support and Australian project management.
100% Quality Testing
Every harness receives 100% continuity and pinout testing and visual workmanship inspection before shipment. Recorded electrical test results support production lot traceability; additional verification follows the agreed release criteria.
Cable Harness Types We Manufacture
Power, signal, hybrid, vehicle, ruggedised, and panel harnesses for equipment installation
Power Distribution Cable Harnesses
Heavy-gauge cable harnesses for power distribution in industrial equipment, switchgear, UPS systems, and battery packs. Rated up to 600V AC/DC with properly sized conductors from AWG 4 to AWG 16.
Signal & Data Cable Harnesses
Low-voltage cable harnesses for sensor networks, communications, and data acquisition systems. Shielded and twisted-pair options for EMI-sensitive applications in mining and medical equipment.
Hybrid Power + Signal Harnesses
Combined power and signal cable harnesses that consolidate multiple cable runs into a single assembly. Reduces installation time, weight, and potential failure points in complex equipment.
Automotive & Vehicle Cable Harnesses
Cable harnesses for passenger vehicles, commercial trucks, buses, agricultural equipment, and specialty vehicles. Designed for engine bay, cabin, and chassis applications.
Ruggedised Cable Harnesses
Heavy-duty cable harnesses engineered for extreme Australian conditions. UV-resistant jackets, IP67/IP68 sealed connectors, and chemical-resistant materials for mining, marine, and outdoor installations.
Control Panel Cable Harnesses
Pre-terminated cable harnesses for electrical control panels, PLC cabinets, and switchboard assemblies. Arrives labelled, tested, and ready to install -- reducing panel build time.
Technical Capabilities
Wire & Cable Options
Manufacturing Capabilities
Specifications depend on the selected conductors, connectors, protection materials, and installation requirements. Electrical ratings, environmental protection, and test criteria are agreed for the build; the limits below do not apply to every configuration.
Electrical Specifications
| Voltage Rating | Up to 600V AC/DC |
|---|---|
| Current Capacity | Up to 150A per circuit |
| Circuit Count | 1 to 500+ circuits |
| Shielding Options | Braid, foil, spiral wrap; individual and overall shielding |
| Insulation Resistance | >100 MΩ at 500V DC, when specified |
| Hi-Pot Testing | Up to 3kV AC/DC, when specified |
Mechanical & Environmental
| Harness Length | 50mm to 50+ metres |
|---|---|
| Temperature Range | -55°C to +200°C, depending on materials |
| IP Protection | Up to IP68 with the specified sealing configuration |
| Crimp Force Monitoring | Real-time monitoring on every automated crimping cycle |
| Terminal Size Range | 0.08mm² to 25mm² for automated crimping |
| Pull Force Testing | Per IPC/WHMA-A-620 |
| Labelling | Laser, thermal, inkjet |
Connector Families We Work With
Wire Harness Applications
Automotive Wire Harnesses
Engine compartments, dashboards, doors, lighting, EV battery management, powertrain, ADAS, and infotainment, with branch breakouts and sealed interfaces for repeatable installation.
Medical Device Harnesses
Diagnostic equipment, patient monitors, surgical tools, imaging systems, and laboratory equipment. Controlled routing and clear labels support compact enclosures and service access.
Industrial Automation
Robotic systems, CNC machines, conveyors, PLC cabinets, and control panels. Pre-identified looms simplify commissioning and service documentation, with high-flex and EMI-shielded options for motion and noise-sensitive applications.
Mining Equipment
Haul trucks, draglines, underground equipment, sensors, conveyors, and power distribution. Protection and connector sealing address dust, vibration, hydraulic fluids, washdown, and outdoor exposure.
Heavy Duty Equipment
Construction machinery, agricultural equipment, mobile plant, and material handling harnesses with controlled branch breakouts, sealed connectors, and abrasion protection.
Power Tools
Compact battery, trigger switch, motor, LED, charger, and safety interlock harnesses for handheld and outdoor power tools.
Telecommunications
Network equipment, base stations, data centers, and infrastructure.
Energy Systems
Solar panels, wind turbines, battery storage, and power distribution.
Marine & Offshore
Vessel power distribution, navigation electronics, offshore platforms, and subsea equipment use saltwater-resistant harnesses with UV-stabilised jackets and tinned copper conductors.
Replacement & Legacy Looms
Existing looms, samples, photographs, and partial drawings can be reviewed against available schematics. Missing BOM details are resolved into a controlled build package for supplier transfers and ongoing equipment support.
Integrated Box Builds
Machine looms, vehicle sub-looms, control-cabinet looms, power and signal looms, sealed field looms, and integrated harness kits can be supplied within larger electromechanical assemblies.
Controlled Routing and Branch Geometry
A loom must fit the installed product consistently. Branch points, breakout positions, connector orientation, and support features are defined around the equipment, with bend radius, handling, and service access considered before production release.
Installation Control Deliverables
- Routing diagrams, branch lengths, breakout positions, connector clocking, and defined measurement points.
- Released BOM and work instructions covering wires, connectors, labels, tape, sleeving, conduit, and support features.
- Label positions, wire marking, cavity references, marker sleeves, and branch identification for assembly and service.
- Protection specified for abrasion, heat, moisture, chemicals, vibration, EMI, and handling: PVC or cloth tape, braided sleeves, split conduit, heat shrink, grommets, boots, clamps, and breakout strain relief.
- An approved first article and agreed electrical, dimensional, and retention criteria for repeat supply.
Best Fit Projects
Wiring looms suit equipment with fixed branch locations, repeated connector sets, clear circuit identification requirements, or replacement parts that must match a validated sample. They help keep installation and field service consistent across repeat builds.
OEM Supply Lifecycle
From a new equipment design or legacy sample, we define the BOM and routing, confirm fit and service access on a prototype or first article, and move through pilot runs into scheduled supply. Approved labels, branch lengths, work instructions, and test criteria keep subsequent orders aligned with the validated loom.
Wire Harness Manufacturing Process
Design Review
Review requirements, installation constraints, and DFM opportunities
Engineering
Release schematics, BOM, routing, labels, and approved component sources
Prototype
Confirm fit, branch geometry, connector clocking, and service access
Validation
Approve the first article against agreed electrical and physical criteria
Production
Cut, strip, crimp, and assemble on routing boards or 3D jigs to controlled work instructions
Final Test
Verify continuity, pinout, and workmanship; record results, label, pack, and release
Quality Testing and Release Evidence
Automated point-to-point continuity and pinout testing verify every circuit. Visual workmanship checks cover crimp geometry, label placement, and connector seating. Test records provide traceable release evidence for repeat OEM supply.
Application-specific validation can include conductor-to-conductor and conductor-to-shield insulation resistance, hi-pot testing, shield continuity, connector retention, dimensional checks, and environmental testing. Pull force tests and microscopic crimp cross-section analysis check terminal compression and wire fill against the agreed workmanship requirements.
How a typical wire harness manufacturing excellence program runs with us
This is an illustrative description of a representative project type, not a specific customer engagement. As a contract assembler we do not publish customer-identifiable data.
Frequently Asked Questions
What is the difference between a wire harness and a cable assembly?▼
A wire harness typically bundles multiple wires together with protective materials like tape, conduit, or sleeves, while a cable assembly usually consists of cables with connectors at the ends. Wire harnesses are more complex and often include multiple connection points, branches, and specific routing requirements.
What industries use wire harnesses?▼
Wire harnesses are used extensively in automotive, medical devices, industrial machinery, consumer electronics, telecommunications, and robotics. Any industry requiring organized electrical connections benefits from custom wire harnesses.
Can you manufacture wire harnesses with custom specifications?▼
Absolutely! We specialize in custom wire harness design and manufacturing. Our engineering team works with your specifications for wire types, connectors, lengths, routing, and protection requirements.
What is your wire harness manufacturing capacity?▼
We can manufacture from single prototype units to millions of wire harnesses annually. Our facility in Philippines handles high-volume production, while our China facility specializes in rapid prototyping.
Do you provide wire harness design services?▼
Yes, our in-house engineering team provides complete wire harness design services including electrical schematics, routing diagrams, and manufacturing documentation. We can design from scratch or modify existing designs.
What testing is performed on wire harnesses?▼
Every wire harness receives 100% continuity and pinout testing, plus visual workmanship inspection. Insulation resistance, hi-pot, shield continuity, pull force, connector retention, dimensional, and environmental checks are available to suit the agreed application and release criteria.
What is the lead time for custom wire harnesses?▼
Prototype wire harnesses typically take 2-3 weeks after design approval when materials are available. Production lead times depend on complexity, quantity, and component availability, typically ranging from 3-8 weeks. Rush services are available for urgent requirements.
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