Wire harness customization refers to the service of selecting appropriate specifications of wires and connector models based on the specific needs of customer equipment, followed by professional processing and assembly. We have extensive experience in wire harness customization, strictly adhere to industry standards, and provide full-process solutions from design and development to production and delivery, ensuring each wire harness meets high reliability and durability requirements. Product Features: Personalized customization: Customize wire length, color, terminal, and sheath type according to equipment working environment, current carrying capacity, signal transmission, and other needs. Quality assurance: Use high-quality copper conductors and flame-retardant insulation materials, with high connector matching precision, passing multiple tests such as withstand voltage, continuity, and insulation. Efficient delivery: Senior engineers for communication, quick sample production, short batch production cycle, helping customers shorten product time to market. Wide application: Suitable for industrial automation, automotive electronics, home appliances, new energy equipment, medical instruments, and other fields. Technical Specifications: Wire gauge: AWG28~AWG10, customizable as needed. Rated voltage: 300V/600V, passed withstand voltage test. Operating temperature: -40℃~+105℃ (expandable with special materials). Connector types: JST, Molex, TE, Hirose, AMP, and other mainstream brands available. Processing technology: Fully automatic cutting, stripping, crimping, assembly, welding, injection molding. Environmental standards: Compliant with RoHS, REACH, and other requirements. Application Scenarios: Industrial equipment: Internal connection harnesses for PLC control cabinets, sensors, actuators. Automotive electronics: Harnesses for lights, audio, instrument panels, sensors. Home appliances: Harnesses for washing machines, air conditioners, refrigerators, smart home controls. New energy equipment: Harnesses for charging piles, energy storage systems, photovoltaic inverters. Medical instruments: Internal connection harnesses for monitors, ultrasound equipment, rehabilitation devices.
Technical Specifications
| Parameters | Please consult sales for detailed specifications |
| Terminal Type | GX16/20/25 Series Circular Aviation Plug |
| Wire Gauge | 18-22 AWG |
| Rated Voltage | 250V AC/DC |
| Rated current | 5-10A |
| Operating temperature | -40°C ~ +105°C |
| Insulation Material | PVC/Silicone Rubber |
Product Features
- Please contact sales for detailed product features
Application Scenarios
- Home Appliances and Consumer Electronics
Customization of power cords, signal wires, and ribbon cables, meeting ROHS/REACH environmental standards, suitable for white goods and small appliances. - Automotive Electronics and New Energy
Automotive wire harnesses, sensor harnesses, high-voltage connection harnesses, passing TS16949 quality system, resistant to high temperature and vibration. - Industrial Automation and Equipment
Robot harnesses, servo motor harnesses, drag chain cables, high flexibility and bending resistance, suitable for complex industrial environments. - Medical Equipment Wire Harnesses
Medical-grade wire harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What is the minimum order quantity for wire harness customization?
The MOQ for standard products is 1000pcs, but small trial orders can be as low as 100-200pcs. It is recommended to request samples for quality confirmation for the first cooperation.
What terminal types and wire gauges are supported?
Supports full series of terminal crimping (JST/Molex/TE/Hirose, etc.), wire gauge from AWG12 to AWG32, customizable length, color, and stripping size.
What are the quality inspection standards for wire harnesses?
Implemented according to UL 486A standard, including continuity test, insulation withstand voltage test, pull force test, and visual inspection, with full inspection delivery reports provided.
Will wire harnesses age after long-term use? How to extend service life?
Under normal operating conditions, this wire harness has a service life of 10~15 years for silicone rubber material and 5~8 years for PVC material. Factors affecting service life: ① Operating temperature — long-term operation at the upper limit of rated temperature will accelerate aging (service life halved); ② Bending frequency — for frequent bending applications, choose high-flexibility wire harnesses (bending life ≥10 million cycles); ③ Environmental factors — UV, ozone, and chemical solvents will accelerate aging of the silicone rubber outer layer. Recommendations to extend service life: leave a 20% margin in operating temperature, avoid contact with chemical solvents, install protective sleeves during fixed wiring, and regularly check whether the terminal crimp area is heating.
What certifications has this wire harness passed? Can certification reports be provided?
This wire harness has passed UL (United States) and CE (European Union) certification and complies with RoHS environmental protection and REACH regulatory requirements. The UL certification number is traceable, and CE declaration documents are complete. For bulk purchases, the following can also be provided: UL certification copy, material certificate (MDS), SGS environmental test report, and product flame retardant test report. For customers with special certification requirements (such as VDE, CCC, PSE, KC, etc.), please inform us in advance, and certification applications can be arranged separately.
How is the wiring harness waterproofed when used outdoors?
The insulation layer of this machine's wiring harness itself is water-resistant (both silicone rubber/PVC do not absorb water), but for outdoor exposed use, it is recommended to combine the following solutions to enhance waterproofing: ① Use IP67/IP68 waterproof connectors; ② Add waterproof heat-shrink tubing (with hot melt adhesive) at the crimp; ③ Cover the cable with a PVC or PE protective sleeve to enhance mechanical protection; ④ Use potting compound (epoxy resin or polyurethane) at the connection to achieve permanent waterproofing. Combined with the above solutions, long-term underwater connection (10 meters water depth) can be achieved, suitable for scenarios such as LED underwater lights, sewage treatment equipment, and marine wiring harnesses.
What is the temperature resistance range of the wire harness? Can it be used long-term in high-temperature environments?
The temperature resistance range of the wire harnesses in this machine varies by insulation material: silicone rubber insulation -60℃~+200℃ (short-term peak 250℃), PVC insulation -20℃~+105℃. In high-temperature environments (such as automotive engine compartments, around industrial furnaces, and inside new energy vehicle battery packs), silicone rubber wire harnesses must be selected; PVC material will accelerate aging and crack the insulation layer in such scenarios. For low-temperature environments (such as extremely cold outdoor areas) and high-low temperature cycling applications, silicone rubber wire harnesses are also recommended.
What is the difference between new energy vehicle wire harnesses and ordinary wire harnesses?
New energy vehicle (EV/HEV) wire harnesses must meet higher standards: ① Temperature resistance grade — the internal temperature of the battery pack can reach 85~150℃, so silicone rubber wire harnesses must be selected (PVC cannot meet the requirement); ② Voltage resistance grade — high-voltage connection wire harnesses withstand 600V~1000V, far higher than ordinary 300V; ③ EMC shielding — high-voltage wire harnesses require an added braided shielding layer to prevent electromagnetic interference (EMC, compliant with CISPR 25 standard); ④ Flame retardant requirements — VW-1 + low smoke zero halogen (LSZH); ⑤ Vibration resistance — terminal crimping must not loosen under high-frequency vibration environments (vehicle operation); ⑥ TS16949 automotive quality management system certification. Ordinary wire harnesses do not meet the above requirements and are prohibited for use on new energy vehicles.
What is the flame retardant rating of the wire harness? Does it comply with the UL VW-1 standard?
The flame retardant rating of this wire harness reaches UL VW-1 (vertical burn test), which is the minimum flame retardant requirement of the UL 758 electronic wire standard. Higher flame retardant ratings are optional: UL VW-1 + vertical burn, UL FT2 (horizontal burn), UL VW-1 + FT2 dual certification. Significance of flame retardant standards: For a wire harness that passes VW-1, in the vertical burn test, after 5 times of 15-second burning, the flame self-extinguishes within 60 seconds, does not ignite the cotton cloth below, and has no burning drips. For applications with high fire protection requirements (such as inside new energy vehicle battery packs and medical devices), it is recommended to select a wire harness with a higher flame retardant rating.
What is the insulation material of this wire harness? Does it meet environmental protection requirements?
The insulation material of this harness uses silicone rubber (Silicone Rubber) or PVC, with the corresponding material selected according to different model specifications. Silicone rubber withstands temperatures from -60℃ to 200℃; PVC withstands temperatures from -20℃ to 105℃. The entire series of wires complies with RoHS 10-item testing and REACH SVHC screening, contains no lead, mercury, cadmium, or other harmful substances, and third-party SGS test reports can be provided. Electronic wires exported to North America must meet the UL VW-1/FT2 flame retardant rating; those exported to Europe must meet the CE Low Voltage Directive.
What is the conductor material of this wire harness? Bare copper or tinned copper?
This product uses stranded tinned copper wire conductors, balancing conductivity and corrosion resistance. Bare copper conductivity is approximately 101%IACS, and tinned copper is approximately 98%IACS (difference only about 3%). Advantages of tinning: oxidation resistance is 3~5 times stronger, solderability is better (avoiding solder non-wetting issues), and corrosion resistance is significantly improved. For scenarios requiring high reliability such as new energy vehicles and outdoor equipment, it is recommended to prioritize tinned copper wire harnesses.
What after-sales services are available after purchasing wire harnesses?
Yingna Technology wire harness products have a standard warranty of 2 years. During the warranty period, free repair or replacement is provided for damage not caused by human factors. Domestic customers receive 48-hour response and repair completion within 7 working days; overseas customers can arrange repair by DHL/FedEx. Products beyond the warranty period are provided paid repair services (cost approximately 30~50% of a new product). Lifetime technical support is provided, including wire harness selection consultation, terminal processing solutions, and quality problem diagnosis. Annual framework agreement customers enjoy value-added services such as priority production scheduling, free samples, and factory inspection support.
