Internal harnesses, box builds and cable assemblies made to your drawing or sample. Crimp, solder or IDC terminations, JST to Molex to TE connectors, sleeving, labelling and 100% electrical test before the carton is closed.
A wire harness takes a bundle of conductors and turns it into a single part an assembler can drop into a product without thinking about it: the right length, the right connector on each branch, the right sleeving, and a label that identifies it. The value is not the wire. It is that the wire arrives already correct.
Which is why almost every harness order starts with a drawing rather than a catalogue. There is no meaningful "standard harness" once the connector, the branch lengths and the enclosure are fixed by someone else's product design.
A photo of a competitor's harness is a starting point for a conversation, not for a quote. Without dimensions and a pinout, the sample that comes back will be an approximation, and that is a wasted round trip for both sides.
This is the one standard that decides whether your harness is acceptable, and it is the one most purchase orders forget to name. Specify it, and inspections stop being arguments about opinion.
| Class | Intended for | What it tolerates | Typical product |
|---|---|---|---|
| Class 1 | General electronic products | Cosmetic variation accepted where function is unaffected | Consumer accessories, non-critical internal wiring |
| Class 2 | Dedicated service equipment | Minor imperfections accepted, continuity of service expected | Appliances, lighting, commercial equipment, most industrial |
| Class 3 | High performance, harsh environment | No strand damage, gas-tight crimp, tight insulation window | Medical, instrumentation, transport, anything failure-critical |
Over-specifying costs money in crimp tooling, inspection time and scrap. Under-specifying costs money in the field. If nobody on your side has decided, the honest default for a domestic product is Class 2, and we will say so rather than quoting Class 3 to look thorough.
A minor nick on a very small proportion of strands, slight variation in insulation clearance above the crimp, and cosmetic marks that do not affect electrical or mechanical integrity. The joint still has to hold its pull force.
Any cut, scraped or severed strand. Insulation must sit flush with the bellmouth, crimp height is measured rather than judged by eye, and every terminal is pull-tested. It is a different process, not a stricter inspection of the same one.
| Family | Where it appears |
|---|---|
| JST | Small pitch board-to-wire, battery and sensor links |
| Molex | Appliance, automotive-adjacent and consumer internal wiring |
| TE Connectivity | Industrial control, sealed connectors, high pin count |
| JAE / Hirose | Compact board-to-wire, fine pitch, portable devices |
| Amphenol | Harsh environment and instrumentation |
| Open barrel terminals | Spade, ring, faston, blade and bullet ends |
| Method | Strength | When to choose it |
|---|---|---|
| Crimp | High, repeatable | Volume, vibration, automotive-style joints |
| Solder | High | Fine pitch, low volume, repairs |
| IDC | Medium | Ribbon cable, fast assembly, flat cable runs |
| Ultrasonic weld | High | Bonding without heat damage to insulation |
| Splice and seal | Medium to high | In-line joins, heat shrink with adhesive |
Brand-name connectors matter when the harness has to match a mating half that is already approved. Where it does not, a pin-compatible alternative is usually cheaper and we will say which one we are proposing instead of substituting silently.
Domestic, commercial and light industrial assemblies. If your product carries a cable inside it, that cable is usually the thing we make.
Refrigeration, laundry, air treatment and kitchen equipment. Internal power and control harnesses, door and panel runs, sensor leads.
Coffee, blending, cooking and personal care. Short internal runs, high-temperature positions, switch and thermostat links.
LED fixtures, drivers, downlights and linear fittings. Board-to-board links, sealed outdoor joints, connectorised fixture ends.
Audio, docks, chargers and accessories. Fine pitch board-to-wire, battery leads, button and display connections.
Sensor and actuator leads, cabinet internal wiring, panel builds. Connectorised at both ends or flying leads as specified.
Dashcams, lighting, telematics and accessory fits. Fused feeds, splices, and harnesses that have to route round a trim panel.
An appliance needs two cables, not one. The harness runs inside the enclosure; the cord that leaves it is a separately approved item with its own plug and its own rating. We build both halves, so the AC power cord range sits alongside the harness work rather than at a second supplier.
Where we stop. We are not an IATF 16949 supplier, so we do not take production-part harnesses for vehicle OEMs, and we do not build implantable or life-support medical assemblies. If your programme needs either, it needs a supplier certified for it, and that is not us. Saying so here saves everyone a long conversation.
In practice, not much, and the terms are used interchangeably. A cable assembly usually means a defined cable with a connector on each end, often with a jacket and a rating. A harness usually means a branched bundle of individual wires with multiple connectors, often internal to a product. The distinction matters less than the drawing, which is why we ask for one either way.
We can, but expect to approve a drawing we produce from that sample. The sample gives us connector series, wire colours and approximate lengths; it cannot tell us the tolerances or the pinout intent. Making the drawing explicit is what stops a good first run from becoming an unrepeatable one.
Either is workable. If you already have an approved connector and a landed cost you like, send it as consignment material and we build around it. If not, we quote the connector into the assembly, and we name the exact series and brand so there is no ambiguity at inspection.
Continuity and pinout on every unit is included, because a harness that is wired wrong is not a harness. Pull-force testing, hipot, insulation resistance and seal checks are quoted according to the sample size your drawing asks for. Third-party inspection is welcome and we schedule around it.
Yes, and it is a fair amount of what we do. Engineering builds are quoted separately from production because the setup cost sits differently. What we will not do is hide the setup cost in a low unit price and recover it on the production order.
Either one is enough to start. Tell us the workmanship class and the quantity, and we will come back with setup cost, unit price, lead time and the test we can show you on the first run.