Assembly Services
Custom Wire Harness
- Circuit-dependent; up to 200 °C and 1000 V with the right wire
- 1 to 60 positions, single or double ended
Custom Wire Harness Manufacturing
Harnesses built to your drawing on Xinya wire — the same UL 758 AWM, harmonised EN 50525 and TUV photovoltaic lines already documented in the wire catalogue on this site. Cut, crimped, sleeved, tested and boxed for your line.
16harness lines
7application groups
1wire supplier, traceable
Send a drawing for quotation Find the right wire Build a specification
What a custom wire harness means here
A wire harness is a made-to-drawing part, so the useful question is not what shapes we stock but what we can build to and what we can prove afterwards. We build to drawings, to samples, to a photograph with a scale in shot, or to a table of from-to points. Every conductor inside the assembly is Xinya wire, which matters because the wire is the one component nobody can inspect once the harness is closed.
That traceability is the reason this catalogue exists in the first place. A customer who queries the temperature rating of a lead inside a harness can be pointed at the published data sheet for the exact UL style it was cut from — its gauge range, its insulation, its certificate reference — rather than at a generic description. Where a harness has to satisfy a standard, the harness carries the standard of the wire inside it, and we name that standard on the quotation.
Assembly is separated from component supply on purpose. Crimp quality is a process question: applicator tooling matched to the terminal series, a measured crimp height, and a pull-test recorded against the lot. A harness that has been crimped with the wrong tool will pass a continuity check in your workshop and fail in the field, and no amount of inspection afterwards recovers an assembly that was built with a rogue joint.
This is an inquiry-first catalogue. Nothing on this site carries a price, because a harness price is a function of conductor gauge, terminal series, sleeving, test regime and volume, and any single figure would be wrong by a factor of two in either direction. Send the specification and the quotation names the wire, the connector, the crimp and the inspection method.
Browse harnesses by application
Seven application groups, each built on the wire lines that suit that environment.
Automotive & Transport
Vehicle, battery-pack, marine and off-road harnesses built for vibration, heat and water ingress, on tinned copper and sealed terminations.
Energy & Renewables
Battery management, energy-storage and photovoltaic harnesses, built on the 1000 V and 1500 V DC wire lines held in the wire catalogue.
Industrial & Automation
Control-panel, machine and continuous-flex harnesses with ferruled conductors, printed circuit identification and terminated shields.
Electronics & Signal
Shielded data, communication and encoder assemblies where the shield termination and the pair geometry decide whether the signal survives.
Appliance & Lighting
Domestic appliance and luminaire harnesses at volume, with high-temperature leads at the hot end and sealed entries on outdoor fixtures.
Medical & Laboratory
Device wiring assemblies selected on cleaning chemistry, bend radius and gauge, with lot-level process records supplied alongside the part.
Assembly Services
Cut-strip-crimp leads, over-moulded and potted assemblies, and the general build-to-drawing service that sits behind every other harness line.
All harness lines
Each line states the wire it is built on, the conductor range, the termination style and the inspection method.
Automotive & Transport
Automotive Wire Harness
- Up to 105 °C, 300 V; higher on the harnesses that need XLPE
- 2 to 60 circuits per connector, multi-branch looms
Automotive & Transport
EV High-Voltage & Battery Pack Harness
- 1000 V DC and 1500 V DC rated wire; 125–150 °C conductor temperature
- 2 to 8 power circuits, plus sense and interlock lines on the same assembly
Energy & Renewables
Energy Storage & BMS Harness
- Up to 1000 V DC on power circuits; 105 °C typical
- 8 to 120 sense positions in one harness, split across module groups
Energy & Renewables
Photovoltaic (Solar) Harness
- 1500 V DC, 90 °C ambient on the TUV PV lines
- Single pair to 6-way string harnesses, plus branch and combiner layouts
Industrial & Automation
Industrial Control & Machine Harness
- Up to 600 V and 105 °C; 1000 V on UL1032 where the panel needs it
- 2 to 120 conductors per loom, single and double ended
Industrial & Automation
Robotics & Drag-Chain Harness
- Up to 600 V and 105 °C on the UL shielded multi-conductor lines
- 2 to 40 conductors, plus shielded pairs for encoder and bus signals
Medical & Laboratory
Medical Device Cable Assembly
- 30 V to 300 V; 105 °C PVC and 150–200 °C fluoropolymer options
- 1 to 40 conductors; fine-gauge low-voltage runs are typical
Appliance & Lighting
Home Appliance Wiring Harness
- Up to 300 V; 80 °C and 105 °C PVC styles cover most internal wiring
- 1 to 30 circuits, dominated by single and double-ended leads
Appliance & Lighting
LED Lighting & Fixture Harness
- 300 V to 600 V; 105 °C to 200 °C depending on proximity to the board
- 1 to 12 circuits per luminaire, plus dimming and control pairs
Electronics & Signal
Communication, Data & Signal Harness
- 30 V to 300 V; 80 °C and 105 °C multi-conductor cable
- 2 to 50 conductors; twisted pairs and individually shielded groups
Electronics & Signal
Sensor & Encoder Cable Assembly
- 30 V to 300 V; 80 °C to 105 °C on the shielded multi-conductor lines
- 4 to 15 conductors — power pair, A/B/Z channels, optional temperature pair
Assembly Services
Terminal & Crimped Wire Leads
- Follows the wire selected; 30 V to 600 V, 80 °C to 200 °C
- Single lead to multi-leg assemblies with 2 to 30 terminations
Assembly Services
Over-Moulded & Potted Cable Assembly
- Follows the wire; up to 105 °C moulding compounds
- 1 to 20 circuits; single, split and daisy-chained mouldings
Automotive & Transport
Marine, RV & Off-Road Harness
- Up to 600 V, 105 °C on the PVC and XLPE lines
- 2 to 40 circuits; separate bilge, helm and house looms are typical
Industrial & Automation
Switchgear & Control Panel Harness
- 600 V standard, 1000 V on UL1032 where the schedule requires it
- Loomed in sections of 10 to 60 conductors for manageable installation
How a harness order runs
Four steps, and the first two are free.
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01
Specification
Send the drawing, the sample or the from-to table. If something is missing we come back with a specific question rather than an assumption.
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02
Quotation
The reply names the wire style and its data sheet, the connector series, the crimp specification, the sleeving, the test regime and the lead time.
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03
Sample
One set is built on hand tools and submitted for fit and function. Tooling is only committed once the design stops changing.
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04
Production
Volume runs on applicator tooling with crimp-height verification and a pull-test per lot, packed with the inspection record.
The wire platform behind every harness
Harnesses are only as good as the wire inside them, and the wire is the one thing a buyer cannot check after the fact. Every conductor in these assemblies comes from the catalogue published on this site: the UL 758 AWM hook-up and control lines, the harmonised EN 50525 cable, the fluoropolymer range for high temperature, and the TUV and UL photovoltaic lines for DC work.
That means a harness quotation can name a UL style whose gauge range, insulation material and certificate reference are already published — and it means that if you later need to change a conductor, the replacement is a catalogue line rather than a phone call.
Questions buyers ask before ordering a harness
What do you need from us to quote a wire harness?
A drawing is ideal, but it is not the only way in. A photograph of the existing part with a ruler in shot, the connector part numbers, or a table of from-to points with wire colours will all get you a quotation. The more of the harness we can see, the fewer assumptions sit in the price.
Which wire do you use inside a custom harness?
Xinya wire throughout: UL 758 AWM styles such as UL1007, UL1015, UL10002 and UL2464 for North American equipment, H05V-K and H07V-K for European machinery, and the TUV photovoltaic lines where the harness runs DC. If your drawing names a style we do not list, ask — the catalogue is a subset of what the factory runs.
Do you build prototypes?
Yes. A single set for fit and function testing is normal and is quoted separately from production volume. Prototypes are built with hand tools; tooling is only committed once the design stops moving.
How is continuity checked?
Every position on every assembly is checked against the from-to list, and the result is recorded against the lot. Insulation resistance and dielectric withstand are added where the drawing calls for them.
What is the smallest order you will take?
There is no fixed floor, but the economics change sharply with volume because tooling and setup dominate a short run. Tell us the annual quantity and we will quote the sensible starting batch.
Request a wire harness quotation
Tell us the style, AWG, colour and quantity — or attach nothing and just describe the requirement. We reply to every enquiry.