Custom Waterproof Cable Assembly Solution
Wires provides custom waterproof cable assemblies for marine vessels, automotive systems, and outdoor equipment, designed to achieve reliable IP67/IP68 protection. With stable manufacturing processes and efficient production, we ensure consistent quality and dependable delivery for your projects.
Our Global Wire Harness Clients
Wires, with over 20 years of expertise as a professional automotive wiring harness manufacturer, leverages shared manufacturing principles between AI wiring harness production and automotive systems. The AI wiring harnesses we provide deliver high-speed, stable, and reliable performance.
High IP Protection Rating Components
The waterproof and dustproof performance of cable assemblies is defined by their Ingress Protection (IP) rating (IP67/IP68), ensuring reliable operation in harsh and demanding environments.
| IP Protection Rating | |||
|---|---|---|---|
| 0 | Zero Protection | No protection | 0 |
| 1 | Protection against solid objects larger than 50 mm, preventing contact with large external objects. | Designed to provide reliable protection against vertically falling water droplets, helping maintain stable performance in basic moisture exposure conditions. | 1 |
| 2 | Protection against solid objects larger than 12 mm, preventing contact with fingers or similar-sized objects. | Protection against direct water sprays up to 15° from the vertical, ensuring reliable performance under light spray and angled exposure conditions. | 2 |
| 3 | Protection against solid objects larger than 2.5 mm, preventing entry of tools or thick wires. | Protection against direct water sprays up to 60° from the vertical, ensuring stable performance under moderate spray and wider-angle exposure conditions. | 3 |
| 4 | Protection against solid objects larger than 1 mm, preventing entry of small wires and fine particles. | Protection against water sprays from all directions with limited ingress, ensuring reliable performance under multi-directional exposure conditions. | 4 |
| 5 | Limited protection against dust with no harmful deposits, ensuring reliable operation in light dust environments. | Protection against low-pressure water jets from all directions with limited ingress, ensuring stable performance under continuous multi-directional spray conditions. | 5 |
| 6 | Fully protected against dust, ensuring complete sealing against dust ingress for reliable performance in harsh environments. | Protection against strong water jets (e.g., ship deck conditions) with limited ingress, ensuring reliable performance under high-pressure washdown environments. | 6 |
 | Protection against higher-pressure water jets, ensuring stable performance under demanding washdown conditions. | 6k | |
| Protection against temporary immersion (15 cm to 1 m) for up to 30 minutes, ensuring reliable performance during short-term submersion conditions. | 7 | ||
| Protection against temporary immersion of at least 1 m, ensuring reliable performance under deeper submersion conditions. | 8 | ||
| Protection against prolonged immersion under pressure, ensuring reliable performance in continuous submerged conditions. | 9 | ||
WIRES Waterproof Cable Assembly Products
Wires provides end-to-end services from design to production, supporting custom cable assemblies for reliable performance across diverse commercial applications.
Waterproof (IP68) RF Cable Assembly
Waterproof D-Sub Rectangular Male Cable Assembly
This cable assembly features a multi-seal design for enhanced environmental protection. In addition to a sealing ring at the connector interface, it uses compression or potting-type sealed cable glands at exit points, along with sealed connector housing joints. It is well suited for aviation, marine, and heavy-duty outdoor equipment where reliable sealing performance is required.
Waterproof M-Type Cable Assembly
Why Choose WIRES?
Wires leverages its strengths to deliver fast turnaround, consistent quality, a wide range of cable assemblies, and customized solutions tailored to your application needs.
Fast Delivery
Wires ensures fast production and delivery, helping reduce downtime and support urgent project timelines.
Diversification
Wires provides a wide range of customized cable solutions to support diverse applications, from automotive systems to outdoor equipment.
Personalized Services
Wires’ professional team provides tailored customization support, guiding product selection and delivering solutions that match your specific application needs.
Unparalleled Manufacturing Capability
WIRES‘s customized solutions meet your specifications with superior technical expertise.
Custom Waterproof Cable Assembly Services
Based on your application requirements, we manufacture waterproof cable assemblies using multiple termination and sealing methods, supporting protection levels up to IP67/IP68 and operating environments typically ranging from -40°C to 105°C.
For overmolded connectors, we utilize:
- High-strength waterproof plugs to ensure sealing between conductors, cable jackets, and connectors
- O-rings and pre-installed sealing gaskets to enhance ingress protection
- Optimized overmolding processes for improved mechanical strength and long-term durability
For non-molded assemblies, we provide:
- Cable connectors with diverse sealing solutions, including USB, RF, circular, and D-sub interfaces
- Potting (resin sealing) techniques for enhanced moisture and dust resistance
- Panel-mount connectors compatible with sealing gaskets to achieve IP-rated enclosure protection
Custom Waterproof Cable Initial Design
We begin by thoroughly understanding your requirements and collaborating closely during the prototype development stage to validate design feasibility. This ensures the cable assembly maintains stable performance and sealing reliability in harsh environments such as moisture, dust, vibration, and temperature variations.
WiresFab Customized Services
WiresFab provides a wide range of custom cable assemblies tailored to your requirements, including cable lengths (50 mm–10 m+), insulation types (PVC, TPE, silicone), waterproof connector options (IP67/IP68), and shielding configurations (foil, braid, or hybrid).
Our solutions support diverse industries such as consumer electronics, automotive, motorcycles, and medical applications, ensuring reliable performance across different use environments.
WiresFab Quality Assurance
We strictly follow approved prototype samples throughout production and perform rigorous quality testing, including 100% continuity checks and visual inspections, to ensure every wiring harness delivered matches the validated design.
Flexible Order Quantity
We support both low-volume prototypes and high-volume production to meet different project stages. For large orders, we offer phased deliveries and scheduled shipments to help reduce inventory pressure and support your supply planning.
Looking for a Reliable Custom Wire Harness & Cable Assembly Partner?
Guaranteed Quality & Safety
Compliant with IPC/WHMA-A-620 standards, ensuring reliable performance in every wire harness and cable assembly.
Customer Reviews of WIRES
Customer reviews of WIRES' custom wiring harness services
This rice transplanter solves the problem of wire harnesses breaking easily! The bent sections are protected by spiral sleeves, ensuring that the wires remain intact even after tens of thousands of twists, significantly extending the overall service life.
The lightweight design of electric bicycle wiring harness is really great! The weight has been reduced by 30% compared to the original factory, and the battery life has increased by 5 kilometers. The wiring is also particularly neat.
The Geely special wiring harness is tightly sealed, and the original plug is plug and play. The modified audio system lights up once, saving 3 hours of labor costs!
Frequently Asked Questions
Customers choose WIRES not only for the value we deliver, but also for our responsive and detailed support. Here are some of the frequently asked questions we’ve compiled.
What protection rating do Wires’ waterproof cable assemblies achieve?
Wires provides waterproof cable assemblies with protection levels such as IP67 and IP68, designed to prevent the ingress of moisture and fine particles for reliable operation. Higher protection solutions can also be developed based on your specific application and environmental requirements.
What factors should be considered when designing waterproof wiring harnesses?
When designing waterproof wiring harnesses, the following key factors should be considered to ensure reliable sealing and long-term performance:
- Waterproof connectors: Selection of connectors with appropriate IP ratings (e.g., IP67/IP68)
- Sealing methods: Use of O-rings, gaskets, potting (resin sealing), or other waterproof techniques
- Harness structure: Choosing between semi-encapsulation or loose routing based on application needs
- Installation design: Proper routing and mounting to avoid stress, gaps, or water ingress points
- Wire processing: Cutting methods, stripping quality, and whether twisting or shielding is required
- Termination sealing: Use of waterproof plugs, overmolding, or sealed terminals at connection points
Does Wires provide waterproof samples?
Yes, Wires supports prototype and sample orders to enable testing and validation before mass production. We have delivered samples to 200+ customers, helping verify sealing performance, fit, and reliability to ensure the waterproof cable assemblies meet your requirements.
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