Harness Builder
A wire harness is quoted from the specification, and the specification is normally spread across a drawing, an email and a part number that only one person has. The builder below puts the whole thing on one screen. Set the approval, the cable, the colours, the length, how each end is prepared and which connector brand the assembly is built on, and the panel on the right writes the specification as you go.
Nothing on this page is a price. When the configuration is complete it is handed to the quote form at the bottom of the page, and a person comes back with construction, tooling, availability and lead time against exactly what you set.
Configurations we are asked for most
Each of these opens the builder with the answer already loaded, so a requirement can be checked in one click and the resulting link kept in a project file or passed to a colleague.
- Automotive body loom, 12 ways105 °C, 300 V, DIN 47100 colours, both ends tinned, Molex housings.
- EV battery pack high-voltage harness125 °C, 600 V UL, 4 ways, both ends tinned, HongXing connectors, IP67 sealed.
- Control panel harness, 16 ways105 °C, 600 V UL, 18 AWG, ferruled conductors for terminal blocks.
- Appliance wiring harness, JST105 °C, 300 V, 6 ways, both ends tinned, JST housings.
- Photovoltaic string harness, 1500 V DC90 °C, 1500 V DC on EN 50618 cable, 2 ways, IP68 branch connectors.
- Encoder / sensor cable assembly80 °C, 300 V shielded, 8 ways in twisted pairs, IP67, 2 m.
- Medical device internal wiring105 °C, 300 V, 10 ways in the 11-colour standard, one end tinned.
- Marine / off-road sealed loom125 °C, 600 V, 20 ways, IP68, both ends tinned for vibration duty.
- LED luminaire lead, 2 ways105 °C, 300 V, 150 mm, tinned one end, JST housing and 2.8 mm disconnect.
- Cut, strip, tin and ferrule leads80 °C, 300 V, 20 AWG, 150 mm, both ends tinned, ferruled for a terminal block.
What you can specify
Everything below is a real option on the form. The cable side is drawn from the Xinya wire catalogue on this site, so the conductor and the finished assembly come from one supplier and one certificate file.
Cable and conductor
| Option | What is available |
|---|---|
| Approval on the conductor | UL 758 AWM under file E170689, EN 50525 harmonised (HAR), TUV / EN 50618 and IEC 62930 photovoltaic cable, and PSE for the Japanese market. |
| Temperature | 60 °C to 250 °C continuous. Your figure is matched against the published rating of each catalogue style. |
| Voltage | 30 V to 1500 V DC, matched against the published rating of each style. |
| Insulation material | PVC, SR-PVC, XLPVC, PE, XLPE, XLPO, FRPE, mPPE and fluoropolymer lines (FEP / ETFE / PFA). |
| Conductor size | 4 AWG to 36 AWG. |
| Conductor construction | IEC 60228 class 5 and class 6, bunched stranded, rope-lay for continuous flexing, or solid. Bare copper, tinned, silver-plated or nickel-plated. |
| Shielding | Unshielded, foil, braid, or foil plus braid with a drain wire. |
| Circuits | 1 to 64 ways. Above one way the recommendation prefers a multi-core construction. |
| Colour | Single colour, the 10-colour sequence to DIN 47100, the 11-colour UL AWM standard, twisted pairs in colour and white, or a custom selection from the standard palette. |
Cutting, termination and the bought-in parts
| Option | What is available |
|---|---|
| Cut length | 1 mm to 100 m, with tolerance from ± 0.5 % to ± 10 mm, or + 2 / − 0 mm. Unit can be set to millimetres, centimetres, metres or feet. |
| Strip length | 2 mm to 50 mm per end, set independently of the tinning. |
| Tinning | Neither end, one end (end A or end B), or both ends. Hot-dip, electroplated, or a conductor that is already tinned in the wire. Tinned length is set separately from the strip length. |
| Terminals | DIN 46228 ferrules with colour coding, twin ferrules for two conductors, ring terminals M3 to M6, fork and spade, pin, bullet, quick-disconnect in 2.8, 4.8 and 6.3 mm, butt splices, soldered and sleeved. Plating in tin, nickel, gold flash or selective gold. |
| Connector brand | JST, Molex, HongXing — or a customer-specified brand and OEM part number. |
| Pitch | 1.00 mm to 7.92 mm. |
| Housing material | PA66, PA66-GF30, PBT, PPS, LCP, PVC boot or silicone, in UL 94 V-0 grades where the application requires it. |
| Contact type | Crimp with an open or closed barrel, IDC, solder cup, board-in, screw clamp or press-fit. |
| Contact plating | Tin, gold flash, gold at 0.5 µm or 1.0 µm, or nickel-free. |
| Locking | Friction, latch, latch with connector and terminal position assurance, screw-lock coupling, bayonet, threaded circular, or panel-mount fixing. |
| Sealing | IP67, IP68, IP69K and IP6K9K. The wire seals and cavity plugs the housing needs are included per position. |
| Strain relief | Heat-shrink boot, over-mould, grommet, strain-relief clip, circular backshell, or a fully potted assembly. |
| Sleeving | PET braid, tinned-copper braid, fibreglass, spiral wrap, split conduit, braid with heat-shrink ends, or lacing cord. |
| Heat-shrink | 2:1 and 3:1 polyolefin, 4:1 adhesive-lined, PTFE, silicone or PVDF. |
| Overall jacket | None, PVC, PUR, TPE, silicone or FEP. |
| Splices | Ultrasonic weld, crimp splice, solder splice with heat-shrink, IDC tap, or a busbar and terminal block. |
| Marking | Printed heat-shrink sleeve, wrap-around label, flag label, colour-code rings, laser marking, QR or barcode label, or inkjet on the jacket. |
| Test | 100 % continuity with the tester recorded against the parts, dielectric withstand at your figure, and a crimp pull test to IPC/WHMA-A-620 or UL 486A-B — on a sample basis or on every crimp. |
| Documentation | Wire list, from-to list, dimensioned 2D drawing, 3D STEP model, first-article inspection report, PPAP level 3, IMDS entry, RoHS declaration, REACH SVHC statement, material certificates, electrical test report, crimp height record and first-article photographs. |
| Packaging | Bulk carton, coil, individual bag, boxed kit for one machine, ESD bag, tray or pallet. |
How the cable recommendation works
As you set the temperature, voltage, approval, insulation, gauge, shielding and circuit count, the panel searches the cable catalogue and returns the styles that meet all of it. A line qualifies when its published rating is at least your figure, so asking for 80 °C also returns the 105 °C and 150 °C lines.
The results are ranked by margin rather than by rating, because a higher rating is not free — it normally means a different insulation compound, a thicker wall and a higher price. The first result is therefore the cheapest cable that is still correct. Every style links to its product page, so the rating, the certificate file number and the construction data can be checked directly.
Where a line carries two published figures, such as 600 V / 750 V or 90 °C wet / 105 °C dry, the recommendation matches against the lower one. Three styles in the catalogue — UL1533, UL2547 and UL2571 — are rated by temperature only, because the UL style itself does not specify a voltage; they drop out as soon as a voltage is required rather than being guessed at.
If you set more than one circuit, the recommendation narrows to multi-core constructions. Where none meets the combination, it says so and falls back to the single-conductor lines, because a multi-core cable would be built to the same conductor specification rather than not existing.
When the form does not cover what you need
A builder can only offer choices it already knows about. A harness with a moulded strain relief on a specific angle, a terminated shield with a defined transfer impedance, a twisted pair with a specified lay length, or a connector that is not in the list above, is still an ordinary day in a harness shop — it just needs to be written down rather than selected.
Use the last section of the form for anything the options do not reach, and attach or reference your drawing. The specification the builder produces already carries the application, the approvals, the cable rating, the colours, the cut length, the end preparation, the connector brand and the test and documentation level, which is most of what a first quotation needs.
Questions about the builder
What do I need to send to get a custom wire harness quoted?
A drawing or a from-to list is the fastest route, but it is not required. The builder on this page covers the same ground: the cable approval and rating, the style and gauge, the colours, the cut length, how each end is prepared, whether the ends are tinned, and which connector brand and series the assembly is built on. Fill in what you know, leave the rest, and send it.
Which cable do you use for the conductors?
The harness is built on Xinya AWM wire from the catalogue on this site, so the conductor and the finished assembly come from one supplier and one certificate file. As you set the temperature, voltage, approval and gauge in the builder, the panel recommends the catalogue styles that meet all of it, ranked with the tightest fit first, and links to each product page so the rating can be checked directly.
Can you crimp terminals from a specific brand, such as JST or Molex?
Yes. The builder lists the brands we build on: JST, Molex and HongXing, plus other customer-specified brands and OEM part numbers. Name the brand, the series or the part number and the quotation will be against that housing and contact, not a generic equivalent. If you need a series outside the three listed brands, choose “Other brands” and write the series or part number in the field beside it.
Can the ends be tinned instead of fitted with terminals?
Yes, and the builder treats it as a separate choice from the terminals. Tinning can be applied to neither end, one end or both ends, and the appropriate length is set separately, because a tinned end and a crimped end rarely want the same strip length. Hot-dip tinning is the default because it holds the strands together and stops them splaying when the wire is pushed into a terminal block.
Can the assembly be sealed for a wet or washdown environment?
Yes. Set the ingress protection in the connector section and the build includes the wire seals and cavity plugs the housing needs, per position. IP67, IP68, IP69K and IP6K9K are all available, and the sealing choice feeds through to the strain relief and the sleeving so the finished assembly is consistent rather than sealed only at the plug.
What documentation can come with the parts?
The builder lets you select any of: wire list, from-to list, dimensioned 2D drawing, 3D STEP model, first-article inspection report, PPAP level 3, IMDS entry, RoHS declaration, REACH SVHC statement, material certificates, electrical test report, crimp height record and photographs of the first article. 100 % continuity testing is on by default and the tester number is recorded against the parts.
Send the configuration
The specification is already in the fields below. Add your contact details, adjust anything the form above could not express, and send it.
Send this configuration
Tell us the style, AWG, colour and quantity — or attach nothing and just describe the requirement. We reply to every enquiry.