Custom Wire Harness Solutions

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Custom Wire Harness Solutions

Precision-Engineered for Your Exact Requirements

  • Tailored Designs – From prototype to mass production
  • Industry-Specific Compliance – Medical, Automotive, Industrial & More
  • Fast Turnkey Service – 15-Day Standard Lead Time

 

Key Features:

  • 100+ Material Options – Silicone, PVC, TPE, XLPE & more
  • Any Connector Configuration – Molex, TE, Amphenol, JST & custom molds
  • Full Testing & Certification – UL, CE, RoHS, IATF 16949 ready

 

Why Partner With Us?

  • 30+ Years Expertise – Your drawings → finished product, error-free
  • Cost Optimization – Value-engineered designs save 15-30%
  • Global Logistics – FOB/DDP terms, 48hr quoting

Specifications

Conductors

Material Options:

High-purity oxygen-free copper (99.99% OFC)

Tinned copper for corrosion resistance

Silver-plated copper for high-frequency applications

Custom Configurations:

AWG 40 to 4/0 (0.08mm² to 120mm²)

Ultra-fine strand for flexibility (up to 0.03mm strands)

Solid core available for rigid applications

Separator

Shielding Options:

Individual pair shielding (foil + braid)

Overall spiral or braided shielding (85-95% coverage)

Drain wire configurations

Separation Technology:

PTFE tape wrapping

Non-woven fabric layers

Corrugated conduit separators

Voltage Rating

Standard Ranges:

Low voltage: 30V to 300V (electronics)

Medium voltage: 300V to 1kV (industrial)

High voltage: 1kV to 35kV (specialty applications)

Custom Solutions:

Hi-pot tested up to 50kV

Surge protection designs available

Insulation & Jacket Materials

Material Options:

Medical: USP Class VI silicone

Industrial: Oil-resistant PUR

Automotive: Cross-linked polyethylene (XLPE)

Consumer: Halogen-free TPE

Custom Features:

Dual-layer insulation

Abrasion-resistant textures

Color-coding per your specs

Resistance Properties

Performance Standards:

Conductor resistance: As low as 0.5Ω/km (12AWG)

Insulation resistance: >100MΩ at 500VDC

Dielectric strength: 1500VAC minimum

Special Capabilities:

Controlled impedance designs

RFI/EMI optimized configurations

Temperature Range

Standard Operating Ranges:

-80°C to +260°C (silicone options)

-40°C to +105°C (PVC standard)

Extreme Environment Solutions:

Cryogenic-rated (-200°C)

Continuous +300°C available

Related Products

UL4348 Halogen-Free Wires

UL4348 Specifications Sheet   Pitch (mm) Conductor Insulation Resistance  At 20C Ω/km   Dielectric Strength (Vac,1min) Size (AWG) Construction (No/mm) Dia. (mm) (No.) Thickness (mm) O.D (mm)        

Automotive Standard Wire Harness

Automotive Standard Wire Harness Specifications Conductor Insulation Max Resistance (Ω/km, 20°C) Dielectric Strength (VAC, 1min) Size (AWG): 8-20 Material: XLPE Construction: Thickness: 0.6-1.0mm 133/0.3mm (8AWG) O.D: 4.5-8.2mm ≤2.1 (8AWG)

Consumer Electronics Wire Harness

Consumer Electronics Wire Harness Specifications Conductor Insulation Max Resistance (Ω/km, 20°C) Dielectric Strength (VAC, 1min) Size (AWG): 28-36 Material: Halogen-free TPE Construction: Thickness: 0.15-0.3mm 41/0.05mm (28AWG) O.D: 0.8-1.5mm ≤230

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