Wire Harness & Cable Assembly FAQ

No. We are a custom wire harness and cable assembly manufacturer and integrator — not a component distributor. We don't sell reels of wire or loose connectors off the shelf. What we do is source the right wire, connectors and terminals and integrate them into a finished, tested assembly built to your specification. The value we add is in the build, the integration and the validation, not in moving raw components.

Yes. A formal drawing is helpful but not essential to get started. We can reverse-engineer from a physical sample, or work from clear photos plus measurements and a wire list. From whatever you give us we produce a manufacturing drawing for your approval before anything goes into production. If a critical detail is missing — overall length, wire type, the BOM or the pinout — we send you engineering questions rather than guessing, so the first article matches what you actually need.

Send us a drawing or specification (PDF, STEP, a sample or even a marked-up photo and wire list) through our quote form or by email. For a clearly defined assembly we usually return a quotation within about 24 hours. Where the design needs clarification, our engineering team comes back with questions first so the price and lead time we quote are the price and lead time you get.

Our MOQ is low. Prototypes can start from just a few pieces, scaling up to volume production of thousands. The main thing to watch is custom-coloured wire: a non-standard colour can carry a per-colour reel minimum (roughly 200–500 m), so very small runs in an unusual colour may attract a small extra cost. Standard colours avoid that altogether.

Yes. You're welcome to consign your own connectors, terminals or specialty cable and we'll build around them — useful when you have an approved vendor list or already hold stock of a long-lead part. Otherwise we source everything ourselves to your BOM. Either way the components are integrated and tested as part of the finished assembly.

We work across the full range. As a rough guide: PVC insulation suits roughly 80–105°C, silicone around 150–200°C, and PTFE/FEP (Teflon) up to about 200°C. One trap worth knowing — some FEP wire is only rated to 105°C unless the high-temperature grade is specified, so we always confirm against the datasheet. For small terminals, Teflon/FEP usually seats better than silicone: silicone's larger outer diameter and softer wall can struggle to crimp cleanly into tiny contacts.

Yes. Standard insulation colours are stocked and carry no extra cost or lead-time impact. A non-standard colour is available too, but it usually comes with a per-colour reel minimum (around 200–500 m) and may add a small cost. In most cases it doesn't extend the lead time — just let us know your colour-coding scheme and we'll flag anything that triggers a reel minimum.

Yes. We build strictly to the pinout you provide, and we produce a wiring diagram for your approval before production. If we spot what looks like a pinout error, we don't silently change it — we confirm the correction with you in writing and update the approved drawing first. Everything traces back to a revision you've signed off.

Overmoulding is typically PVC, with TPU/TPE available, and UL-recognised materials where an NRTL listing is required. For strain relief we use heat-shrink (including adhesive-lined), moulded backshells and grommets. For protection and bundling we offer PVC sleeving, expandable braided sleeving, corrugated loom/conduit for abrasion resistance, and EMI shielding sleeve. We'll recommend the combination that suits your environment and assembly method.

Depending on your EMC needs we can use shielded cable (foil, braid or both), an overall shield over otherwise unshielded pairs, or add an EMI shielding sleeve over the bundle. We'll advise the most effective approach — including how the shield is terminated, which matters as much as the shield itself — rather than just over-specifying.

Yes. We provide printed labels, heat-shrink printing and wire markers exactly as your drawing calls out. We can print identification directly onto heat-shrink tubing and add UL-rating wire markings where required, so each assembly is traceable and field-serviceable.

We routinely integrate Molex, JST, TE/AMP, Deutsch, Hirose, M12/M8, FAKRA, LEMO, Harwin, Amphenol and common RF series, among others. Send us a part number and we'll work to it; if a part is obsolete or carries a long lead time, we'll propose a form-fit-function alternate for your approval. You're also welcome to consign your own connectors.

We build to IPC/WHMA-A-620, the recognised standard for wire harness and cable assembly workmanship. Testing includes 100% electrical continuity, hi-pot where specified, crimp pull (tensile) tests, plus dimensional and visual inspection. Test data is recorded and supplied with the assemblies.

Yes. Before any volume run we produce a first article — a representative first sample — with inspection data for you to approve. A sample or FAI fee may apply on some projects, and it's often credited back against the production order once you proceed.

We build to the approved drawing revision, full stop. If a discrepancy appears — say a length that doesn't match what you expected — we confirm which revision you're working to and resolve it before or at the first article stage. That's why every quote, drawing and build references a specific revision number: it removes the ambiguity.

We use RoHS-compliant materials and can supply the component-level RoHS certificates. Note that a finished harness generally won't carry a single overarching RoHS certificate, so we provide the underlying wire and component certs instead. UL-recognised wire (for example UL758 AWM) and CSA-certified wire (for example CSA C22.2 No. 210) are available on request — just specify what your application needs.

Our manufacturing operates under ISO 9001 quality management, with IATF 16949 for automotive work and ISO 13485 for medical assemblies as applicable. Assemblies are built to AS/NZS expectations for the Australian market and to IPC/WHMA-A-620 workmanship, with UL-recognised and RoHS-compliant materials available on request.

Samples typically take around 1–2 weeks. Volume production generally runs about 3–6 weeks after drawing approval and payment, with the timeline driven mostly by connector and terminal availability rather than the build itself. If you have a hard deadline, tell us early — we can often expedite or pre-order long-lead components in parallel.

Finished assemblies are packed anti-static where required, clearly labelled and protected with foam to survive transit. We ship on EXW, FOB or DDP terms to suit your import preferences, by DHL, FedEx or UPS for air freight, or by sea for larger volumes into Australian ports.

The fastest start is to send your drawing, sample or specification through our quote form. We'll review it, raise any engineering questions, and return a quotation. We're happy to sign an NDA before you share sensitive designs — just let us know and we'll have one in place before any files change hands.