EV Battery Cable Assembly Manufacturer
Custom high-voltage wiring harnesses and battery interconnect cables for BEV, PHEV, HEV and commercial electric vehicle platforms — engineered to ISO 6469, manufactured under IATF 16949.
Why EV Battery Cable Assemblies Demand Specialist Manufacturing
The transition from internal combustion to electric powertrains places demands on cable assemblies that conventional automotive wire harness manufacturers are not always equipped to meet. EV battery cable assemblies operate at voltages from 400 V to 800 V DC — an order of magnitude above the 12 V and 48 V circuits found in traditional vehicles — and carry continuous currents of 200 A to 500 A in traction applications. These parameters require conductors with much larger cross-sections (typically 35 mm² to 120 mm²), insulation rated to IEC 60228 Class 5 or Class 6 flexibility, and connector systems tested to disconnect under load without arcing.
At Nexharn Connectivity, we manufacture EV battery cable assemblies across the full voltage spectrum: low-voltage battery management system (BMS) wiring, high-voltage battery module interconnects, traction motor harnesses, and DC fast-charging interface cables. Every assembly is produced in our IATF 16949-certified factory and ships with full material traceability, electrical test records, and RoHS/REACH compliance documentation.
Types of EV Battery Cable Assemblies We Manufacture
High-Voltage Battery Module Interconnects
Rigid or semi-flexible busbars and flexible HV cables connecting prismatic, pouch, or cylindrical cells within battery modules. Available in copper or aluminium conductors, with XLPE or silicone insulation rated to 600 V or 1000 V. Crimped or welded terminations to HV blade or bolt-lug connectors.
Traction Motor Wiring Harnesses
Three-phase HV harnesses from the inverter to the drive motor, carrying AC currents at 400 V or 800 V platform voltages. Orange XLPE outer jacket (per ISO 6469-3 / SAE J1344 HV colour code), shielded to reduce EMI. Lengths from 0.5 m to 3 m, with OEM-compatible connectors at both ends.
Battery Management System (BMS) Cables
Low-voltage signal and power harnesses connecting the BMS controller to cell voltage sensors, temperature probes, current sensors, and contactors. Multi-conductor assemblies with individual screened pairs, robust PVC or LSZH jackets, and sealed connectors rated to IP67 for underbody routing.
DC Fast Charging Interface Cables
Inlet-to-battery cables for CCS (Combined Charging System), CHAdeMO, and GB/T 20234.3 charging interfaces. Sized for 150 A to 500 A DC peak, with integrated pilot and proximity signal conductors. Thermally stable PVC or XLPO jackets for charging bay environments (−40 °C to +90 °C).
Thermal Management Cables
Mixed harnesses combining power, data, and coolant monitoring conductors for liquid-cooled battery packs. Jacketed assemblies with thermistor leads, flow sensor wires, and pump power cables routed as a single managed harness to reduce assembly time on the production line.
Contactor and Precharge Wiring
Auxiliary cables connecting the main HV contactors, precharge resistor, and service disconnect to the battery junction box. Dual-conductor with individual insulation colour coding per IEC 60445, confirmed connectivity marked on the assembly label.
Safety Standards and Compliance
EV battery cable assemblies must comply with a layered set of safety standards addressing electrical insulation, mechanical robustness, fire behaviour, and system-level safety. We manufacture to the following standards as standard:
| Standard | Scope | Relevance |
|---|---|---|
| ISO 6469-1:2019 | EV safety — on-board energy storage | HV cable insulation and colour-coding requirements |
| ISO 6469-3:2021 | EV safety — protection against electrical hazards | Connector disconnect-under-load, HVIL, isolation monitoring |
| UL 2251 | Plugs, receptacles and couplers for EVs | North American market connector certification |
| SAE J1344 | Marking of EV electrical components | Mandatory orange colour coding for HV cables >60 V DC |
| UN/ECE R100 | Approval of EVs with regard to battery system | EU type approval — cable assembly requirements in battery packs |
| LV 216 / LV 112 | Automotive wire and harness specifications (OEM) | German OEM supplier requirements for wire insulation and marking |
| IATF 16949:2016 | Automotive quality management system | APQP, PPAP, FMEA, control plan for cable assembly production |
| RoHS 2 / REACH SVHC | Hazardous substance restrictions | Mandatory for EU vehicle type approval and export markets |
Custom EV Cable Assembly Specifications We Support
- Voltage rating: up to 1,000 V DC (UL/IEC) or 1,500 V DC (rail applications)
- Current rating: 30 A (signal) to 500 A (traction/fast charge)
- Conductor material: oxygen-free copper (standard) or aluminium alloy (weight-optimised)
- Conductor cross-section: 0.5 mm² to 120 mm²
- Insulation: XLPE (125 °C rated), silicone (180 °C), XLPO (halogen-free), PVC (economy)
- Outer jacket: orange XLPE (HV), black PVC (LV), LSZH (fire-safety environments)
- Connector families: Amphenol HV-100, TE/Tyco HVSL, Yazaki EV, Aptiv Delphi 2.8 HV, custom bolt-lug
- EMI shielding: foil + drain wire, braided copper shield, or double-shielded for 800 V platforms
- IP rating: IP67 (standard) or IP69K (wash-down environments)
- Operating temperature: −40 °C to +125 °C (standard XLPE) or up to +180 °C (silicone)
All specifications are confirmed by a golden sample approval process before production kick-off. We support PPAP (Production Part Approval Process) Level 3 submission for OEM and Tier-1 customers.
Electric Vehicle Applications
Battery Electric Vehicles (BEV)
Full-EV platforms (passenger car, SUV, commercial van) require HV battery packs from 40 kWh to 200 kWh. Our assemblies serve cell-to-module, module-to-module, and pack-to-inverter interfaces at 400 V and 800 V platform voltages.
Plug-in Hybrid Vehicles (PHEV / HEV)
Hybrid drivetrains combine a smaller HV battery (8–30 kWh) with an ICE. Cable assemblies interface between the traction battery, starter-generator, and DC/DC converter. Both 48 V mild-hybrid and 400 V full-hybrid configurations are supported.
Commercial and Heavy-Duty EVs
Electric buses, delivery trucks, and construction machinery operate at higher voltages (up to 800 V) and currents (up to 500 A continuous). We manufacture reinforced traction cables with abrasion-resistant jackets for floor-mounted routing in commercial vehicles.
E-Bikes and Light Electric Vehicles
Lower-voltage (36 V to 72 V) assemblies for e-bike battery packs, e-scooter powertrains, and golf carts. Smaller cross-sections (0.5 mm² to 10 mm²), IP65-rated connectors, and colour-coded wiring to EN 15194.
Why Choose Nexharn Connectivity for EV Cable Assemblies?
- IATF 16949 certified — full automotive quality system with APQP, FMEA, and control plan documentation
- Dedicated HV assembly line — separated from LV production; ESD-controlled workstations; HV-rated test equipment
- 100% electrical testing — continuity, HV withstand (hipot), and insulation resistance test on every assembly
- Vertical integration — raw wire, connectors, and overmould tooling all in-house for lead times of 4–6 weeks
- Flexible MOQ — prototype quantities from 10 pcs; mass production from 500 pcs
- Full compliance documentation — RoHS, REACH, PPAP Level 3, material data sheets supplied with each order
Ready to discuss your EV battery cable assembly requirements? Contact our engineering team with your specification, target quantity, and timeline — we will respond within one business day with a technical review and indicative quotation.