What is the minimum order quantity (MOQ)?
At WIRES, MOQ is defined based on wire harness type and complexity:
Simple harnesses (consumer electronics or small appliance internal harnesses)
MOQ: 500–2,000 pcs
Moderately complex harnesses (industrial, agricultural machinery, low-voltage automotive harnesses)
MOQ: 1,000–5,000 pcs
Highly complex harnesses (e.g., engine, chassis, instrument panel harnesses)
MOQ: 5,000+ pcs
Fully customized harnesses
MOQ: typically 2,000–5,000 pcs, depending on design complexity and cost factors.
Can samples be provided before mass production?
Yes. WIRES can provide 1–5 samples for evaluation before mass production.
Is there a charge for samples?
We offer flexible options:
- Simple, low-value samples: If you show clear project intent (drawings, quantities, timeline), we charge 50% of the standard sample fee, which will be deducted from your bulk order.
- Complex, high-value samples: For products with complex circuits, specialized connectors, or shielding, standard sample fees apply. These fees are fully refunded if your order exceeds 10× the sample value.
Sample Lead Time
Samples are typically completed within 1–3 weeks and shipped via international express.
This process ensures customers can verify quality, fit, and performance before committing to large-scale production.
Accepted Payment Methods ？
At WIRES, we support the following payment terms:
- FOB + 100% advance T/T
- FOB + Deposit (30%–50%) + Balance (70%–50%) upon receipt of B/L copy via T/T
- FOB + Letter of Credit (L/C)
These flexible options ensure secure and efficient transactions for international orders.
Delivery Lead Times for Custom Orders
At WIRES, lead times are determined by order volume and material requirements, with clear timelines confirmed during order evaluation.
Small-batch custom orders (100–500 pcs):
Due to lower volumes and spot material procurement, pre-production preparation takes longer.
Lead time: 2–5 weeks
Large-volume custom orders (1,000+ pcs):
Higher volumes require extensive material sourcing and production planning, including coordination with suppliers and process verification.
Lead time: 8–10 weeks
Note: Lead times may vary due to external factors such as shipping conditions, weather, or tariff changes.
Are there discounts for bulk orders?
Yes. WIRES offers multiple bulk order discount options:
- Direct Price Discounts: Tiered pricing based on quantity (1K, 5K, 10K, 50K), with lower unit costs at higher volumes.
- Free Product Allocation: Complimentary units included (e.g., 10 extra units for a 10K order) for maintenance or backup.
- Logistics Support: For orders over 5K units, up to 20% of local transport costs (to Chinese customs) may be covered.
- Engineering Support: Cost optimization through material selection or minor design improvements, sharing savings while maintaining performance and reliability.
These options help maximize cost efficiency and value for large-scale orders.
What do I need to get a quote?
To provide an accurate quote, WIRES requires key details such as materials, dimensions, thickness, and order quantity.
- Preferred: Detailed technical drawings or specifications
- Alternative: For simple products, basic sketches or samples are acceptable
Providing complete information helps ensure faster quotations and precise pricing tailored to your project.
Do you support customized designs?
Yes. WIRES provides end-to-end custom design services, with clear technical inputs to ensure precise alignment with your requirements.
Required Input Documents:
- Electrical schematic: wire gauge, connector models, fuse/relay locations
- 2D layout diagram: branch lengths, tie points, protective materials, shielding needs
- Application parameters: temperature range, vibration, waterproof rating, EMC requirements
Customization Service Process:
- Requirement confirmation: 1–3 business days to define environment, application, and special needs
- Design & verification: 3D models + 2D drawings; 5–10 business days, including up to 3 free revisions
- Sample production: 7–15 business days; 1–3 samples with inspection reports (fees credited to bulk order)
- Mass production:
- Small batches (>100 pcs): 15–20 days
- Large batches (>1,000 pcs): 30–45 days (partial shipments available)
Important Notes:
- Final drawings require customer approval and sign-off
- Post-production design changes may incur additional costs
- Cost optimization options available (e.g., replacing PTFE with XLPE can reduce costs by ~40%)
This structured process ensures accuracy, efficiency, and reliable product performance from concept to delivery.
What types of connectors does WIRES offer?
WIRES’ core strengths include:
Automotive connectors
Terminal connectors (JST, TE, Molex), high-voltage connectors, high-speed data connectors, and RF connectors
Consumer electronics connectors
Board-to-board, wire-to-board, FPC/FFC, I/O, and battery connectors
Industrial connectors
M-series circular connectors, Harting Han-series rectangular connectors, aviation connectors, and terminal blocks
Communication and data center connectors
RJ45 connectors, fiber optic connectors, and backplane connectors
Medical device connectors
LEMO circular connectors and various customized medical connectors
This wide portfolio ensures high compatibility, reliability, and performance across diverse applications.
Do you support customized designs?
Yes. WIRES provides end-to-end custom design services, with clear technical inputs to ensure precise alignment with your requirements.
Required Input Documents:
- Electrical schematic: wire gauge, connector models, fuse/relay locations
- 2D layout diagram: branch lengths, tie points, protective materials, shielding needs
- Application parameters: temperature range, vibration, waterproof rating, EMC requirements
Customization Service Process:
- Requirement confirmation: 1–3 business days to define environment, application, and special needs
- Design & verification: 3D models + 2D drawings; 5–10 business days, including up to 3 free revisions
- Sample production: 7–15 business days; 1–3 samples with inspection reports (fees credited to bulk order)
- Mass production:
- Small batches (>100 pcs): 15–20 days
- Large batches (>1,000 pcs): 30–45 days (partial shipments available)
Important Notes:
- Final drawings require customer approval and sign-off
- Post-production design changes may incur additional costs
- Cost optimization options available (e.g., replacing PTFE with XLPE can reduce costs by ~40%)
This structured process ensures accuracy, efficiency, and reliable product performance from concept to delivery.
What types of connectors does WIRES offer?
WIRES’ core strengths include:
Automotive connectors
Terminal connectors (JST, TE, Molex), high-voltage connectors, high-speed data connectors, and RF connectors
Consumer electronics connectors
Board-to-board, wire-to-board, FPC/FFC, I/O, and battery connectors
Industrial connectors
M-series circular connectors, Harting Han-series rectangular connectors, aviation connectors, and terminal blocks
Communication and data center connectors
RJ45 connectors, fiber optic connectors, and backplane connectors
Medical device connectors
LEMO circular connectors and various customized medical connectors
This wide portfolio ensures high compatibility, reliability, and performance across diverse applications.
Logistics Methods
WIRES offers multiple logistics options:
International Express Delivery
Ideal for sample shipments, with couriers assisting in customs clearance. Partners include DHL, TNT, and EMS.
International Air Freight
Suitable for small-batch deliveries, providing faster transit times than sea or rail with high security.
International Sea Freight
The most common method for bulk shipments, offering cost efficiency and flexible container options.
International Rail Transport
Suitable for bulk orders, mainly serving the China–Europe corridor.
How to Protect Wiring Harnesses During Transportation?
Moisture Prevention Measures:
At WIRES, wiring harnesses are packaged in durable cardboard boxes.
- Internal moisture protection: Uses PE bags or aluminum foil bags (selected based on customer requirements), with 3 desiccant packets per box for added humidity control
- External moisture protection: Products are palletized and secured with stretch wrap before shipment to ensure stability and moisture resistance
Shock Absorption Solutions:
To prevent damage during transport vibration and handling:
- Bubble wrap protection for full harness coverage
- Custom EVA foam for wrapping, cushioning, or separation
- Custom-molded foam liners for high-value or precision wiring harnesses
All packaging methods are fully supported by WIRES, and we can also strictly follow customer-specific packaging requirements when provided.
How to Handle Quality Issues or Returns ？
At WIRES, if shipped products have quality issues, we typically resolve them in the following ways:
- Irreparable products: We will directly reship replacement units to the customer.
- Repairable products: We coordinate with a customer-approved third-party service provider for repair, with all costs covered by WIRES.
- Standard orders: We provide 0.1% of the order value in free spare products for future maintenance or replacement use.
This ensures fast resolution, minimal downtime, and reliable after-sales support for all customers.
Quality Control Measures in Production
Incoming Material Inspection
Wires and terminals are sample-tested based on supplier reports, verifying wire strand count, wire diameter, color, terminal plating thickness, and dimensions. Connectors are inspected for dimensional accuracy against official drawings.
Process Inspection
- Wire cutting/crimping: Initial, patrol, and final inspections per CP requirements; patrol checks every 2 hours per shift
- Pre-assembly: follows the “insert, listen twice, pull back” verification method
- Assembly process: confirms seal installation, secondary locking of connectors, and primary locking of terminals
Final Inspection
- 100% dimensional checks using tape measures/steel rulers
- 100% electrical testing on dedicated harness test benches
- Appearance inspection of materials, clips, tie wraps, and labeling
- Additional sampling audits by Quality Department for full-dimension and functional verification
Traceability Assurance
Each harness is assigned a unique serial label, enabling full traceability and rapid root-cause identification in case of issues.
Can We Visit Your Factory?
Of course. WIRES warmly welcomes factory visits at any time.
Please contact us in advance via email or phone to schedule your visit so we can arrange proper reception and support for your trip.
Can You Send a Product Catalog and Price List?
We offer custom manufacturing services, and most products are produced based on customer drawings or samples, so a complete catalog and fixed price list is not available.
However, we can:
- Provide standard product references with indicative pricing if needed
- Offer fast quotations based on your drawings, samples, or technical requirements
Simply share your details with us, and WIRES will provide a quick and accurate quote tailored to your project.
What is your delivery time?
For WIRES:
- Standard products: shipped within 1–3 business days after payment is received
- Molded/custom products: production cycle is typically 1–3 weeks
For faster processing, please send your requirements, drawings, or samples, and we will provide a free quotation and accurate delivery time quickly.
How do you ensure product quality?
At WIRES, we ensure product quality through strict control across every stage:
- Raw material control: All materials are strictly inspected before production
- Process control: Key manufacturing steps are monitored to ensure consistency and precision
- Pre-shipment inspection: Each product is thoroughly checked before delivery to ensure it meets required standards
This end-to-end quality control system ensures that you receive reliable, stable, and high-quality products every time.
I need to produce 50,000 parts in a week. Can you do it?
Yes, WIRES can support urgent and high-volume orders.
Our standard lead time is 2–3 weeks, but for time-sensitive projects such as 50,000 pcs/week, we can:
- Prioritize production scheduling
- Allocate additional manufacturing capacity
- Fast-track materials procurement when needed
If your project has a strict deadline, we will evaluate your requirements and provide a feasible expedited production plan accordingly.
Can I get some samples?
Yes, WIRES is happy to provide samples.
- Standard products: Free samples are available; shipping cost is paid by the customer.
- Custom products: Sample and shipping costs are required, but these will be deducted from your official order after confirmation.
This allows you to evaluate quality and fit before mass production.
How long does it take to prepare samples?
At WIRES, sample lead time depends on the material procurement cycle:
- Common materials: samples are ready within 3–7 days
- Special materials: lead time depends on sourcing conditions, and we will confirm the exact schedule based on procurement
This ensures fast turnaround while maintaining stable quality and material accuracy.
Can you customize products?
Yes, WIRES mainly provides custom manufacturing services based on customer drawings or samples, ensuring products fully meet your design, performance, and application requirements.
Can you add marks to the products or packaging?
Yes, WIRES can customize product and packaging markings according to your needs.
We support:
- Stamping
- Laser marking
- Screen printing
- Custom brand logos or identifiers
This allows you to achieve clear product identification and brand customization for both components and packaging.
Why can’t I find the product I want on your website?
At WIRES, many products are custom-made for clients under confidentiality agreements, so they cannot be fully displayed online.
Our manufacturing capabilities cover a wide range of custom cable assemblies and components, even if they are not shown on the website.
If you don’t see your product, please submit a request form or email us directly—we can often produce it and provide a surprising level of customization support and solutions.
Can you provide drawings for us?
Yes, WIRES can support drawing development.
If you don’t have formal drawings, you can provide photos, samples, or product parameters, and we will create detailed engineering drawings for your confirmation before production.
What certifications can you provide?
At WIRES, we can support a wide range of certifications based on your project requirements.
Please let us know the required standards or market regulations, and we will assist in preparing and applying for the relevant certifications accordingly, ensuring compliance with your target industry and region.
What payment methods do you support?
At WIRES, we mainly accept:
- T/T (Telegraphic Transfer)
- L/C (Letter of Credit)
For sample orders or small orders, we also support:
- PayPal
These options provide flexible and secure payment solutions for different order types.
What trade terms do you support?
At WIRES, we support multiple international trade terms, including:
- EXW (Ex Works)
- FOB (Free on Board)
- CIF (Cost, Insurance & Freight)
- FCA (Free Carrier)
- CIP (Carriage and Insurance Paid To)
- DAT / DAP (Delivered at Terminal / Delivered at Place)
- And other customized shipping terms based on customer needs
This flexibility allows us to better support global customers and different logistics requirements.
I don’t understand the import process well. Can you ship the goods directly to my warehouse?
Yes, WIRES can ship directly to your warehouse.
We support DDP (Delivered Duty Paid) terms, which means we handle:
- International shipping
- Import customs clearance
- Taxes and duties
You will receive the goods directly at your specified address with no additional import work required.
What types of wire harness manufacturing services do we provide?
At WIRES, we offer full-cycle wire harness manufacturing services, including:
Prototyping & Product Development
- Advanced production and prototyping equipment
- Managed by experienced project engineers
- Customer-involved design and rapid prototype development
- Engineering support to assist customer design teams
- Optimization of performance, aesthetics, and manufacturability
Cost Optimization Services
- Process optimization to reduce manufacturing costs
- Competitive pricing solutions based on project requirements
Inventory & Supply Management
- Inventory planning based on customer forecasts and demand
- Flexible scheduling aligned with delivery requirements and production capacity
This ensures efficient development, cost control, and stable supply for all wire harness projects.
How do we ensure high quality in wire harness processing work?
At WIRES, quality is ensured through a structured, end-to-end engineering and production control system:
Our estimators and project managers first analyze customer drawings and specifications in detail to ensure all technical and performance requirements are fully understood and achievable.
In the front-end planning stage, we establish controlled procedures, process routings, and inspection plans, translating customer requirements into clear manufacturing instructions and quality standards.
During production and inspection, our skilled operators and quality teams strictly follow defined processes and inspection protocols to ensure every step complies with customer requirements.
This integrated approach ensures consistent quality, traceability, and reliable performance across all wire harness products.
What services can we provide?
At WIRES, we offer full-cycle engineering and manufacturing support:
- Oversee the entire product design and development process
- Integrate products into full-scale production
- Optimize designs for manufacturability and assembly efficiency
- Develop and improve prototypes based on existing customer designs
- Modify and refine prototypes to better meet performance and production requirements
What are the common applications of wire harnesses?
Wire harnesses from WIRES are widely used across multiple industries, including:
- Automotive industry: vehicle wiring systems, control modules, lighting, seats, and infotainment
- Motorcycle industry: electrical systems, lighting, and control units
- Agricultural machinery: tractors, harvesters, and other field equipment wiring systems
- Home electronics: appliances, consumer electronics, and internal device wiring
These applications ensure stable power transmission, reliable signal connection, and safe system operation across different environments.
What is WIRES wire harness manufacturing process?
Wire harness manufacturing at WIRES is a controlled production process that transforms raw materials into fully functional harness assemblies using automated equipment and skilled labor.
A key step in this process is crimping, which requires high precision and professional expertise to ensure reliable electrical performance.
WIRES combines specialized manufacturing equipment with experienced operators to process various raw materials and complete accurate assembly of the final product, ensuring consistent quality and stable performance.
What is the difference between WIRES technology for wire harness manufacturing?
At WIRES, wire harness production uses multiple key technologies across the entire manufacturing process:
Fully automatic crimping
Fully automatic crimping is the core process of joining wires and terminals. WIRES mainly uses high-speed automated crimping equipment for efficiency and consistency, along with multiple methods such as:
- Fully automatic crimping
- Semi-automatic crimping
- Semi-automatic articulation
- Fully automatic articulation
Pre-assembly
Pre-assembly prepares components before final assembly. Connectors and terminals are installed in advance to improve efficiency. Key methods include:
- Grid-based wire placement by wire diameter
- Multi-connector grid organization
- “Insert, listen, pull” verification method
Assembly process
This is the final integration stage where all parts are combined into a complete harness. It includes:
- Tooling board wiring layout
- Cable tie fixation on boards
- Final positioning and securing of all components
Special equipment testing
This is the final and most critical quality step. Dedicated testing equipment verifies:
- Correct wiring sequence
- Proper terminal insertion
- Anti-terminal pull-out integrity testing
These combined technologies ensure high precision, strong reliability, and consistent quality in every wire harness produced by WIRES.
What are the raw materials used in WIRES wire harness manufacturing?
At WIRES, we use a wide range of high-quality materials for custom wire harness production, including:
- Terminals: copper with tin, nickel, gold, or silver plating (welding process)
- Connectors: PA66, PA6, PBT and other engineering plastics
- Wires: various cross-sections such as 0.75 mm², 1.0 mm², 1.25 mm², 1.5 mm², 2.0 mm², etc.
- Cable ties: PA66, PA6 materials
- Adhesive tapes: PVC, BOPP, PET, PE, PP
- Waterproof plugs: silicone, EPDM, fluororubber
Our manufacturing facility is also capable of handling other customized wire harness materials and specifications based on customer requirements.
What types of machines does WIRES have?
At WIRES, we use a variety of advanced equipment for wire harness processing, including:
- Fully automatic crimping equipment
- Fully automatic assembly equipment
- C-type winding machines
- Mobile tooling boards
- Special electrical test benches
These machines ensure high efficiency, precision processing, and reliable quality control throughout the wire harness manufacturing process.
What is fully automated crimping for wire harness manufacturing? How does it work?
Fully automated crimping is a core wire harness manufacturing process where wires and terminals are precisely connected using automated equipment.
In this process, wires are fed into the machine through a wire feeding system, and the terminals are accurately crimped onto the wire ends to form a stable electrical connection.
During crimping, a real-time pressure monitoring system continuously checks the crimping force and quality to ensure each connection meets strict production standards.
Compared with traditional manual crimping, fully automated crimping is:
- Faster and more efficient
- More precise and consistent
- More stable in quality control
Because of these advantages, it is widely used in high-volume and high-reliability wire harness production applications.
What are the advantages of WIRES fully automatic crimping compared with other methods?
- Fast and efficient: Significantly improves production speed and consistency
- Higher precision: Reduces risks of insufficient tension and crimp height deviation caused by manual operation
- Stable quality: Ensures consistent crimping performance for every terminal
- Stronger crimp reliability: Each connection meets or exceeds manual crimp strength standards
- Cost-effective: Improves efficiency while reducing labor-related costs and error rates
What does WIRES wire harness manufacturing inspection process include?
At WIRES, the inspection process is carried out in a structured quality control flow:
Our experienced inspection team begins by reviewing all operating procedures and inspection documents before production starts.
During production, factory operators strictly follow these documents to ensure each process meets specification requirements.
After manufacturing, products are transferred to the inspection area, where professional quality inspectors conduct final checks to confirm whether each wire harness meets acceptance standards before shipment.
What are the advantages of WIRES wire harness manufacturing?
Wire harness manufacturing offers several key advantages:
- Wide material compatibility: Supports a broad range of materials and configurations
- Flexible design options: Allows highly customizable layouts and structures
- High customization capability: Easily adapted to specific application requirements
- High quality standards: Strict manufacturing requirements ensure reliable product performance
- Lightweight & flexible: Easy to transport, install, and integrate into systems
- Cost-effective solution: Balances low cost with high quality and efficiency
- Wide industry application: Suitable for automotive, industrial, and consumer electronics fields
These advantages make wire harnesses a reliable, efficient, and scalable solution across multiple industries.
Why choose WIRES Wire Harness Manufacturing?
WIRES is a professional wire harness manufacturer in China, providing integrated solutions from design to production.
- One-stop ODM & OEM services: Covering product design, engineering design, rapid prototyping, and mass production
- Fully customizable solutions: Flexible options in size, structure, and design to meet different project requirements
- Wide industry applications: Used in automotive, energy, home appliances, agricultural machinery, medical, dental, and more
- Certified manufacturing quality: A high-tech enterprise with certifications such as ISO quality management and environmental management systems
- Reliable engineering support: Advanced technology and manufacturing experience ensure stable, high-performance products
WIRES delivers efficient, flexible, and high-quality wire harness solutions for global customers.
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