Custom wire harnesses are the nervous system of every electromechanical product. Nexharn Connectivity manufactures bespoke wire harnesses for OEMs in industrial automation, medical devices, consumer electronics, telecom, and agricultural machinery — delivering IQ-tested assemblies with controlled build documentation from a vertically integrated facility in Dongguan, Guangdong, China.
Whether your application requires a 3-wire point-to-point harness or a 200-conductor multi-branch trunk with over-moulded strain reliefs and DIN 46228 ferrule terminations, our engineering team works from your schematics, wiring diagrams, or samples to produce a locked Bill of Materials, a dimensional control plan, and a 100%-tested production assembly.
Wire Harness Types and Configurations
| Harness Type | Typical Conductors | Common Applications |
|---|---|---|
| Point-to-Point Harness | 2–20 wires | Sensors, actuators, LED drivers |
| Multi-Branch Trunk Harness | 20–200+ wires | Machine control panels, agricultural equipment |
| Flat Ribbon Harness | 8–64 conductors, 1.27 mm or 2.54 mm pitch | PCB-to-PCB data connections |
| High-Voltage Harness | AWG 12–4 | EV charging stations, solar inverters |
| Shielded Signal Harness | 2–24 shielded pairs | CAN bus, RS-485, EtherCAT installations |
| Overmoulded Harness | Any count | Outdoor machinery, medical handpieces |
Materials and Construction Specifications
| Parameter | Standard Range | Custom Options |
|---|---|---|
| Conductor gauge | AWG 28 – AWG 4 (0.08 mm² – 25 mm²) | Stranded, solid, tinned copper |
| Insulation material | PVC, XLPE, PTFE, Silicone | FEP, ETFE for high-temp applications |
| Jacket material | PVC, TPE, PUR, Nylon braid | TPU, FR-PVC (UL94-V0), LSZH |
| Operating temperature | –20 °C to +105 °C (PVC) | –60 °C to +200 °C (PTFE/Silicone) |
| Voltage rating | 300 V – 600 V | 1000 V for HV harnesses |
| Connectors | Molex, JST, TE, Amphenol, Deutsch | Customer-specified brand + PN |
| Termination | Crimp, solder, IDC, ferrule | Welded, spring-cage on request |
Manufacturing Process
Our wire harness production follows a 7-stage controlled process:
- Wire cutting and marking: Automated wire cutters (Komax and Schleuniger) cut to ±1 mm tolerance with simultaneous heat-shrink marker application.
- Stripping: Servo-controlled stripping to ±0.3 mm strip length; automatic blade adjustment for conductor diameter.
- Crimping: Servo-electric applicators with 100% crimp-force monitoring. Out-of-window crimps are flagged and segregated immediately.
- Sub-assembly: Multi-conductor bundles twisted, laced, or wrapped per the build-specification drawing.
- Connector insertion: Terminal insertion confirmed by insertion-force monitoring (pneumatic insertion fixtures).
- Overmoulding (if specified): Injection moulded strain reliefs in TPE, PA66, or PVC using customer-approved tooling.
- 100% electrical test: Continuity, hi-pot, and polarity verified on dedicated test fixture designed to harness drawing.
Quality Certifications
- ISO 9001:2015 – Quality management system
- RoHS 3 / REACH SVHC – Substance compliance declaration per IEC 62321
- UL AWM – Approved wire styles available (UL 1061, UL 2464, UL 20276)
- CE (LVD / EMC) – EU Declaration of Conformity for applicable harness assemblies
- IATF 16949 – Automotive quality management (select product lines)
Industries and Applications
- Industrial automation: PLC I/O harnesses, servo drive power cables, safety circuit wiring
- Medical devices: patient monitoring leads, diagnostic equipment wiring, cleanroom-assembled harnesses
- Agricultural machinery: tractor and harvester electrical systems, sensor and actuator wiring
- Consumer electronics: appliance internal wiring, display cables, power distribution harnesses
- Telecom: base station power distribution, antenna feeder assemblies, rack-to-rack interconnects
Frequently Asked Questions
What is the minimum order quantity (MOQ) for custom wire harnesses?
Standard MOQ is 100 assemblies for simple point-to-point harnesses and 500 assemblies for complex multi-branch trunk harnesses. Sample runs of 5–20 pieces are available for first-article approval prior to production order commitment.
Can Nexharn replicate harnesses from a physical sample without a drawing?
Yes. Our engineering team can reverse-engineer from a physical sample, producing a dimensional drawing, BOM, and golden sample for your approval before production begins. We charge a one-time engineering fee for this service, which is rebated against the first production order.
What is the typical lead time for custom wire harnesses?
Lead time ranges from 15 to 35 days from drawing approval to ready-to-ship, depending on harness complexity and order volume. Simple harnesses with standard connectors from our inventory ship in 15–20 days. Complex multi-branch assemblies with custom tooling require 25–35 days.
Ready to start? Contact Nexharn with your drawing, sample, or specification requirements for a quotation within 24 hours.