Automotive-grade cable assemblies demand tighter tolerances, harsher environmental certifications, and more robust process controls than commercial-grade wiring. Nexharn Connectivity produces automotive cable assemblies to IATF 16949-aligned quality standards, serving Tier 2 and Tier 3 suppliers, EV charging infrastructure manufacturers, and aftermarket automotive accessory brands worldwide.
From a 2-wire sensor pigtail to a 50-conductor door module harness, our automotive assemblies are built from qualified connector platforms (Aptiv, TE ECONOSEAL, Molex MX150), automotive-grade wire to ISO 6722 or SAE J1128, and crimped with servo-electric applicators running 100% force monitoring.
Automotive Cable Assembly Types
| Assembly Type | Key Spec | Typical Use |
|---|---|---|
| Sensor/Actuator Pigtail | 2–6 wires, sealed connector, IP67 | O2 sensors, solenoids, wheel speed sensors |
| Door Module Harness | 20–80 conductors, branch harness | Window motors, lock actuators, speaker wiring |
| Battery Cable Assembly | AWG 4–2/0, tin-plated terminals | 12 V battery to fuse box, EV 12 V auxiliary |
| EV High-Voltage Harness | 600 V / 250 A, orange jacketed, shielded | EV traction battery to inverter |
| CAN Bus/LIN Wiring | Twisted pair, 120 Ω, drain wire | Body control module, ADAS sensors |
| Charging Inlet Assembly | Type 1 / Type 2 / CCS2 connector | EV onboard charging inlet wiring |
Material Specifications
| Parameter | Specification |
|---|---|
| Wire standard | ISO 6722-1 (automotive low-voltage), SAE J1128 |
| Conductor material | Bare copper or tin-plated copper, AWG 28–2/0 |
| Insulation | PVC (Class B, 85 °C), XLPE (Class D, 125 °C), Silicone (155 °C) |
| Jacket | PVC, TPE, or corrugated conduit |
| Operating voltage | 12 V / 24 V / 48 V / 600 V (HV variants) |
| Temperature range | –40 °C to +125 °C (standard); –40 °C to +175 °C (engine bay) |
| Connector suppliers | Aptiv (Delphi), TE Connectivity, Molex, Amphenol |
| IP rating | IP67 standard for sealed connectors; IP6K9K on request |
Quality Certifications
- IATF 16949 – Automotive quality management system (select product lines)
- ISO 9001:2015 – Base quality management system
- RoHS 3 / ELV Directive – EU End-of-Life Vehicle substance compliance
- REACH SVHC – ICP-MS verified substance declarations
- UL 758 / SAE J1128 – Wire and cable approved for automotive wiring
- ISO 19642 – Road vehicles electrical cables (on request)
Applications
- Traditional ICE vehicle body harnesses and powertrain wiring
- Electric vehicle (EV) high-voltage traction and auxiliary harnesses
- Hybrid vehicle 48 V mild-hybrid wiring systems
- EV charging infrastructure: EVSE station internal wiring, charging inlet assemblies
- Aftermarket automotive accessories: dash cams, lighting kits, performance electronics
- Off-road and heavy-duty vehicle wiring: trucks, buses, construction equipment
Frequently Asked Questions
Does Nexharn produce IATF 16949-certified automotive assemblies?
Our facility operates under an IATF 16949-aligned quality management system with full PPAP capability including dimensional reports, material certifications, and Control Plans. Full IATF 16949 third-party certification is available for dedicated product lines with sufficient annual volume commitment. Please discuss your specific requirements with our sales team.
Can Nexharn supply approved connector brands (Aptiv, TE, Molex)?
Yes. We purchase connectors directly from Aptiv, TE Connectivity, Molex, and Amphenol distribution channels and can provide connector order acknowledgements and certificates of conformance. We do not substitute unapproved generic equivalents without explicit customer approval.
What is the lead time for automotive cable assembly orders?
Lead time is 20–40 days from approved drawing to ready-to-ship, depending on connector lead times and order complexity. For assemblies requiring PPAP documentation, add 5–7 days for documentation preparation and review. Rush production is available for engineering prototype quantities (1–20 pieces) at priority pricing.
Request a quotation for your automotive cable assembly requirements. Provide your drawing, connector PN list, and annual volume estimate for fastest response.