Cable harness manufacturing with 100% continuity testing.

From internal jumpers to sealed branched harnesses, with crimp validation, overmolding, and lot-level documentation per release.

Processes

Automatic cut, strip and crimp.

Wire pre-tinning and pin insertion.

Twisting, bundling and lacing.

Heat-shrink and braided sleeving.

Connector overmolding for sealed assemblies.

Custom formboard construction for branched harnesses.

Internal board-to-board (FFC / FPC, IDC).

Sealed automotive harnesses (Deutsch, Molex, TE Superseal).

Industrial control and signal harnesses.

Power and ground harnesses up to 8 mm² conductor.

Wire types	PVC, XLPE, silicone, FEP, PTFE
Conductor sizes	AWG 30 to AWG 6 (≈ 0.05 mm² to 16 mm² with lug)
Max routine conductor	8 mm² in production cycle
Shielded cable	Foil and braid; drain wire termination supported
Sealed cable	Per drawing (silicone-jacketed, halogen-free, etc.)
Voltage rating	Specified in the drawing; 600 V routine

Pull-force testing per crimp specification — sample plan documented per program.
Crimp height measurement on production samples per shift.
Cross-section analysis on first article and on quality challenges.
Calibrated crimp tools with documented die / wire assignment.
Crimp acceptance criteria aligned with IPC/WHMA-A-620.

Insertion verification (audible click + visual + push-back) on critical connectors.
Overmolding for sealed assemblies in customer-specified or in-house-made molds.
Strain-relief boots installed per drawing.
Connector keying respected and verified at first article.
Sealed connector cavity plugs installed in unused cavities per spec.

Wire list, connector pinout and label sheet attached to each shipment.

Per-unit serial label on request.

Continuity test pass / fail logs.

Crimp pull-force sample reports.

Photo documentation for first article and key revisions.

Wire list with from-pin / to-pin, wire color, gauge, length.

Connector specification per end (manufacturer, MPN, gender, keying).

Formboard drawing (1:1 if possible) with branch lengths and orientation.

Sealing class and overmold material per drawing.

Avoid over-specifying wire colors; standard AWG color codes simplify procurement.
Specify branch lengths with realistic tolerances — a 1 mm tolerance on a 500 mm branch raises rework rate.
Group same-gauge wires where possible — bundle and lacing time drops.
Use sealed connectors only where the application demands them; sealed connectors raise unit cost notably.
If the harness will be hand-installed in the field, provide an installation drawing — production can reflect that in branch orientation.

1. Wire list provided without crimp specification — production defaults to a generic die, pull-force fails the customer test.
2. Formboard drawing in PDF only without 1:1 scale — branch lengths drift.
3. Sealed connector specified but the wire jacket diameter is outside the seal range — first article fails IP test.
4. Label position not defined — labels rotate during installation, become unreadable.
5. Heat-shrink shrink ratio not stated — operator picks a generic ratio, sealing performance varies.
6. No acceptance class stated — Class 2 vs Class 3 inspection criteria diverge significantly.

IPC/WHMA-A-620 Class 2	Standard for industrial / consumer / commercial.
IPC/WHMA-A-620 Class 3	On request — high-reliability programs.
Automotive sealing	IPx7 / IPx9K achievable with overmolding.
RoHS compliance	Default; non-RoHS materials only on explicit request.
REACH SVHC	Material declarations available on request.

Next step

Send your manufacturing package to start scope review.