Custom Wire Harness Manufacturer Trusted For Over 28+ Years

WIRES provides flexible, tailored logistics solutions for custom wire harness samples and bulk orders, covering global delivery needs.

International Express Delivery is ideal for custom wire harness prototypes and small sample batches. WIRES partners with DHL, TNT, and EMS, offering professional customs clearance to ensure fast, smooth cross-border delivery of wire harness samples.

International Air Freight is suitable for small-batch wire harness orders. It offers faster transit times than sea or rail freight and high cargo security, reducing the risk of damage to precision wire harness components.

International Sea Freight is the preferred choice for bulk custom wire harness shipments. With flexible container options (FCL/LCL), it helps optimize logistics costs for large-volume wire harness orders.

International Rail Transport serves bulk wire harness shipments to Europe, particularly along the China-Europe corridor. It balances cost-effectiveness and transit efficiency, providing a reliable option for European deliveries.

This logistics approach ensures fast, secure, and cost-effective shipping for custom wire harness samples and mass production orders worldwide.

Incoming Material Inspection
Wires and terminals are sampled per supplier reports (AQL 0.65 unless otherwise specified). Verify strand count (±2%), wire diameter (±0.02 mm), insulation color (per standard), plating thickness (≥ spec, e.g., ≥0.8 μm), and dimensions (±0.05 mm). Connectors are inspected for dimensional compliance with drawings (±0.05 mm critical features).

Process Inspection
Wire Cutting & Crimping:

• Initial, in-process, and final inspections per CP.
• Patrol inspection every 2 hours/shift (≥4 times/shift).
• Cutting length tolerance: ±1.0 mm.
• Crimp height tolerance: ±0.03 mm; pull force ≥ specified standard (e.g., ≥50 N depending on wire size).

Pre-Assembly:
Follow “insert, listen twice, pull back” procedure; 100% insertion verification.

Assembly:

• Seal installation presence: 100% check.
• Terminal primary locking: 100% verified.
• Connector secondary locking: 100% verified.

Final Inspection

• 100% dimensional check (key dimensions ±1.0 mm).
• 100% electrical testing (continuity, short/open circuit, insulation resistance ≥10 MΩ).
• Visual inspection: appearance defects ≤ AQL 0.65; verify clips/ties integrity and label accuracy (100%).
• Quality sampling: ≥1% of batch for full-dimension and functional re-test.

Traceability
Each harness carries a unique serial number (1:1 traceability). Data retention ≥5 years, enabling rapid root cause identification and containment within 24 hours.

WIRES welcomes visitors to our factory at any time. Please email or call us in advance to schedule your visit.

WIRES sources raw materials directly from OEMs and authorized distributors, ensuring authenticity and high quality for all wire harness components. Each batch includes a unique batch number and original factory packaging, providing full traceability from the supplier to the finished product. Before production, we share all relevant raw material information for your review, ensuring complete transparency and confidence in the materials used for custom wire harnesses.

Molded cable assemblies integrate cables and connectors into a single unit using rigid plastic (such as PVC, ABS, or nylon) or rubber materials. They typically provide:

• Operating temperature range: -40°C to +105°C (standard), up to +125°C for high-performance materials
• Ingress protection: IP65–IP68 for moisture and dust resistance
• Dielectric strength: up to 2.5 kV for insulation
• Durability: resistant to chemical exposure, UV light, and mechanical abrasion

This durable design makes molded cable assemblies ideal for industrial machinery, military equipment, and outdoor wire harness applications.

Overmolded cable assemblies encapsulate existing cables and connectors within a flexible thermoplastic or elastomer layer, enhancing mechanical stress resistance. Key specifications include:

• Bend radius: as small as 4× cable diameter without compromising performance
• Tensile strength: supports up to 50–100 N depending on cable type
• Vibration resistance: withstands 10–200 Hz frequency ranges common in robotics and medical equipment
• Temperature range: -40°C to +105°C (standard), optional high-temp up to +125°C

This reinforcement maintains harness flexibility, making overmolded assemblies suitable for dynamic applications such as robotics, medical devices, and environments with repetitive motion.

WIRES provides comprehensive custom wire harness and cable assembly solutions for automotive, industrial, medical, and EV applications. Our services include:

• Wire processing: cutting, stripping, crimping, soldering, and termination, with wire gauges from AWG 32 to AWG 8 for precision applications.
• Wire harness assemblies: including complex multi-branch designs and high-density connector integration.
• Precision machining: achieving 0.1mm-level length tolerances, specialized bend angles, and non-standard terminal crimping to meet custom mechanical and electrical specifications.
• Value-added services:
  • Fast 24-hour quotation response
  • Custom wire gauges and insulation materials (PVC, TPE, PTFE, XLPE)
  • Appearance and functional testing including continuity, voltage drop, and insulation resistance tests
  • Production support for prototypes, small batches, and mass production orders

Our solutions ensure high-quality, reliable, and cost-effective wire harnesses, suitable for both dynamic and harsh environment applications.