Details
Electronic wire harnesses are key components in electronic devices for transmitting signals and power, composed of multiple wires arranged rationally, insulated, and assembled with connectors. Our electronic wire harness processing service focuses on high-precision, high-reliability customized production to meet various electrical connection needs. Product features include high-quality copper conductors and eco-friendly insulation materials, offering excellent conductivity and strong durability; support for twisted-pair electronic wire harnesses to effectively resist electromagnetic interference and ensure signal stability; support for non-standard customization with rapid prototyping and mass production based on customer drawings or samples; strict quality inspection processes including continuity testing, withstand voltage testing, and visual inspection; modular production to shorten lead times and reduce overall costs. Technical specifications: wire gauge range AWG 18~32, rated voltage ≤300V, rated temperature -40℃~+125℃, insulation materials optional PVC, PE, TPE, etc., compatible connector types JST, Molex, Hirose, etc. Application scenarios widely used in household appliances (air conditioners, washing machines), automotive electronics (on-board sensors, lighting control systems), industrial control (PLC, servo drives), communication equipment, and medical devices requiring high connection reliability.
Technical Specifications
| Parameters | Please consult sales for detailed specifications |
| Terminal type | 3.81mm pitch crimp terminal |
| Wire gauge | 22-28 AWG |
| Rated voltage | 300V |
| Rated current | 5A |
| Operating temperature | -40°C ~ +105°C |
| Insulation material | PVC or UL1061 electronic wire |
Product Features
- Precision crimping process ensures secure terminal-to-conductor connections
- Custom harness lengths, terminal plating, and colors available
- Suitable for PCB board-to-board and board-to-wire connections
- High reliability, verified by insertion/extraction life testing
- Compliant with RoHS and UL certification standards
- Optional waterproofing, shielding, and other special requirements
Application Scenarios
- Household Appliances and Consumer Electronics
Custom 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 wire harnesses, high-voltage connection wire harnesses, passing TS16949 quality system, resistant to high temperature and vibration. - Industrial Automation and Equipment
Robot wire harnesses, servo motor wire harnesses, drag chain cables, highly flexible and bend-resistant, adaptable to complex industrial environments. - Medical Device Wire Harnesses
Medical-grade custom wire harnesses, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What is the minimum order quantity for custom wire harnesses?
The MOQ for standard products is 1000pcs, with small trial orders as low as 100-200pcs; it is recommended to prototype for quality confirmation on first cooperation.
What terminal types and wire gauges are supported?
Full range of terminal crimping is supported (JST/Molex/TE/Hirose, etc.), wire gauges from AWG12 to AWG32, with customizable length, color, and strip size.
What are the quality inspection standards for wire harnesses?
UL 486A standards are followed, including continuity testing, insulation withstand voltage testing, pull force testing, and visual inspection, with full inspection shipping 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.
Can the color of the wire harness be customized?
Any color can be customized; usually provide a Pantone color number or color swatch for color matching. Common stock colors: black, white, red, blue, yellow, green (shipped within 24~48 hours). Custom color MOQ depends on specifications (usually from 1000 meters), lead time extended by 3~5 working days. Printing/marking service: model, LOGO, certification mark, etc. can be printed on the wire harness surface as required; both heat transfer printing and inkjet coding processes are supported. Please provide a printing draft before confirming the printing content to avoid errors.
Can this wire harness be used in medical devices? What standards must it meet?
The standard wire harness of this product is not recommended for direct use inside medical devices. Medical device wire harnesses must meet the IEC EN60601 standard, with requirements: ① low leakage current — ordinary wire harness leakage current ≤0.5mA, medical grade ≤0.1mA; ② biocompatibility — insulation and terminal materials must pass ISO 10993 biocompatibility testing; ③ high isolation voltage — reinforced insulation, isolation voltage ≥4000V; ④ cleanliness — produced in a cleanroom, no ionic contamination. Yingna Technology can customize medical-grade wire harnesses (including EN60601 certification); technical parameters and certification requirements must be communicated in advance, and production will be arranged separately.
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 minimum bending radius of the wire harness? Can it be used for wiring in confined spaces?
The minimum bending radius of this wire harness is 5 times the wire diameter, far smaller than the 10 times wire diameter requirement for ordinary PVC wire. Due to the stranded structure of multiple extra-fine tinned copper wires, the harness offers excellent flexibility and can be routed flexibly in confined spaces such as mobile phones, sensors, automotive door panels, and LED luminaires, and repeated bending is unlikely to break the core. If a smaller bending radius is required (such as robot drag chains), a high-flexibility drag-chain-specific wire harness can be selected.
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.
About Winna Technology
Winna Technology specializes in power adapters, AC/DC cable harness customization, and ultrasonic metal welding equipment R&D and manufacturing, providing one-stop OEM/ODM services.
Our products are CE/UL/FCC/CCC/RoHS certified, with an annual return rate below 0.02%, serving customers in 50+ countries and regions worldwide.
