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ISO9001 ISO13485
ISO14001

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IATF
16949

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IPC-A-610H International
Certification

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Fully Automated
AOI Inspection

rohs
ul
custom wiring harness capabilities

IATF 16949 Certified Automotive Wiring Harness Manufacturer Capabilities

WellPCB manufactures automotive wiring harnesses in-house using calibrated equipment, fixture-based routing, and RoHS-compliant wire and cable. Our comprehensive wiring harness services cover every stage from conductor prep through final electrical testing. Each wire harness build is guided by OEM pinouts and BOMs, with process control covering conductor prep, terminal crimping, connector assembly, and electrical testing.

As an automotive wiring harness manufacturer, WellPCB processes automotive wire using programmable servo-controlled cut-and-strip machines. Conductor lengths from 50 mm to 2000 mm are prepared with insulation stripping tolerances of ±0.5 mm.

We support wire gauges from 40AWG to 120 mm² using XLPE, PVC, and silicone-jacketed types. Optical verification systems confirm cut length and strip depth before the wire is transferred to the automotive wiring harness assembly stations.

Closed-barrel, open-barrel, and flag-style terminals are crimped using pneumatic or hydraulic presses fitted with calibrated applicator dies.

Crimp height is checked using micrometer tools, and all crimps are validated to meet minimum pull-force values according to SAE J2030 and OEM-specific specs.

Connector types include sealed and unsealed housings, with HVIL-compatible terminals supported for high-voltage wire harnesses. Supported systems include Sumitomo, Yazaki Corporation, Deutsch, Molex, JST, and TE Connectivity.

Each automotive harness is assembled on mechanical form boards designed from customer routing diagrams. Harness routes are laid using spot taping, branching fixtures, and sleeving paths.

Grouped wires are bundled using PVC or braided cable sleeving, with concentric layup applied to twisted pairs for EMI-sensitive subsystems. Final layout is verified against drawing overlay sheets or digital inspection systems.

WellPCB’s automotive wiring harness manufacturer expertise extends to high-voltage EV systems using orange XLPE-jacketed cable rated for 600 V, with conductor sizes from 2.5 mm² to 6 mm².

Insulation resistance is tested to 100 MΩ at 500 VDC, and dielectric withstand testing is conducted at up to 1500 VDC for critical battery and inverter paths.

Protective sleeving includes fiberglass, silicone, and PET braided options. Cable routing incorporates bend radius validation and shielding continuity for charge and BMS modules.

Each automotive harness undergoes 100% continuity testing using computer-controlled test benches matched to the harness pinout table. Isolation tests use hi-pot equipment at 500–1500 VDC, depending on the harness type.

Visual inspections include terminal seating, insulation stripping quality, and wire marking legibility, performed at 5x to 10x magnification.

Pull-test and crimp-height logs are recorded for each harness group and linked to serialized QC reports.

All automotive wiring harnesses are serialized with barcoded labels, heat-shrink IDs, and batch metadata.

Labeling options include UV-rated inkjet, laser etch, or printed tags, depending on environmental class.

All wire and cable lots are tracked to supplier documentation and RoHS certificates. Operator IDs, timestamps, and final test logs are attached to each production record for traceable release.

WellPCB supports low-volume runs starting from a single unit, with scalable production for over 10,000 harnesses per part number.

Prototypes are built in 2 to 3 weeks, depending on connector availability and BOM complexity. We source wire, cable, and terminal materials through global cable suppliers, including Digi-Key, Mouser, and Avnet, with full material traceability and component substitution support.

Why Choose WellPCB as Your
Automotive Wiring Harness Manufacturer?

WellPCB is an assembly and wire harness manufacturer that builds all automotive wiring harnesses in-house using fixture-based routing, calibrated press crimping, and 100% test coverage.

Our process control supports high-volume builds with consistent conductor layout, verified terminal compression, and RoHS-traceable wire and cable materials, following IATF 16949 and IPC/WHMA-A-620 Class 3 standards.

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In-House Production, No Outsourcing

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10 Years of Experience in Harness Manufacturing

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Sourcing Partnerships with Global Cable Suppliers

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High-Quality Wire Harness Assembly Standards

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Flexible Volumes from Prototype to Mass Production

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Full Support for Automotive Cable Assemblies

What Types of Vehicles and Harness Builds does WellPCB Support?

WellPCB supplies automotive OEM wire harness solutions to OEMs, Tier 1 suppliers, and aftermarket manufacturers building for electric, hybrid, combustion, and specialty vehicle platforms.

We manufacture to your specifications across full production volumes, including builds for EV drivetrains, combustion engines, off-road equipment, ADAS systems, and low-volume service replacement harnesses.

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Passenger Vehicles and Fleet Cars

Automotive manufacturing

Electric Vehicles and Hybrid Platforms

Automotive Wire Harness with Labels

Heavy-Duty, Off-Road, and Agricultural Equipment

Automotive Printed Circuit Boards Surface Mounted

Autonomous and ADAS-Capable Platforms

Why Is HDI Technology Becoming So Popular in the Automotive Industry

Aftermarket and Service Replacement Automotive Harnesses

Our Automotive Wiring Harness Process

WellPCB manufactures every wiring harness for car applications using a defined technical workflow that begins with customer-supplied drawings and ends with serialized, test-validated harnesses ready for integration.

Our process supports wire harness drawing reviews, BOM traceability, in-line inspection, and scalable transition from prototype to final product manufacturing.

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OEM Drawing & BOM Review

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Routing Diagram and Pinout Mapping

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DFM Feedback and Material Confirmation

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Prototyping and Initial Sample Testing

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Full-Scale Wire Harness Manufacturing

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Electrical, Mechanical, and Visual Testing

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Packaging, Documentation & Shipment

What Types of Wire and Insulation Materials do You Use?

In every wiring harness for car purposes, WellPCB uses stranded copper automotive wire with RoHS-compliant insulation systems including XLPE, PVC, silicone, and fiberglass.

All wire and cable are specified by conductor class, strand count, and voltage rating, supporting high-voltage systems, engine compartments, and interior harness builds across EV, hybrid, and combustion vehicle types.

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Conductor Materials and Sizes

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Primary Insulation Types

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Secondary Sleeving and Shielding

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Color Coding and Wire Marking

What are the Design Considerations for Automotive Wire Harnesses?

Designing automotive wiring harnesses requires optimization for electrical performance, packaging constraints, signal integrity, and mechanical durability. Each wiring harness for car applications must maintain reliable function under voltage load, EMI exposure, and mechanical stress throughout its installed service life.

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Electrical Performance and Safety

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Electromagnetic Compatibility (EMI/EMC) and Grounding

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Strain Relief

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Physical Design and Routing

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Routing Difficulty

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Length, Tolerance, and Outer Covering

How to Order Your Automotive Wiring Harness
submit design

Submit Your Design

Send us your design details (Drawing or Detailed Specifications).

instant quote

Get a Fast Quote

Once your design and specs are received, a fast quote will be sent to you within 24 hours.

payment

Confirm Order & Make Payment

When the quotation is approved, please send the PO or order confirmation, we will proceed with the production after receiving your payment.

specifications

Arrange Production & Inspection

Before production, our technical team will review all details of the drawing/specs again. If everything is OK, the order will start. We'll keep you updated throughout the manufacturing process. After the production is completed, the products will be 100% inspected.

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Packaging & Delivery

When completed, your order will be carefully packed and shipped to you, with shipping documents and tracking information provided.

WellPCB is trusted by millions of
businesses and innovators.

Why Choose WellPCB as Your Wire Harness Manufacturer?

WellPCB stands out among USA wire harness manufacturers by delivering superior quality, advanced solutions, and unmatched reliability. With years of experience serving global markets, WellPCB has earned a reputation as one of the top wire harness manufacturers in the USA.

WellPCB specializes in custom wire harnesses for complex electronic and industrial applications. You can order these assemblies with $100 off using our special offer—delivering high-quality, tailor-made harnesses at competitive rates for your most demanding projects.

team member shao

Hommer Zhao

Founder and Chief Editor – Hommer Zhao

Welcome! I’m Hommer Zhao, the founder and Chief Editor of WellPCB. With years of experience in the PCB industry, I’m committed to making sure our content is both accurate and helpful. We’re proud to serve a growing community of over 4,000 customers worldwide, and our goal is to provide you with the best resources and support. Your satisfaction is our top priority, and we’re here to help you every step of the way!

team member jessie

Jesse Holland

Technical Manager – Jesse Holland

Hi, I’m Jesse Holland, an Engineer and Technical Manager at WellPCB. With years of experience in PCB design and engineering, I’m here to ensure that every project we work on meets the highest technical standards. I lead our team, focusing on precision and innovation, collaborating closely with clients to provide tailored solutions and expert guidance. Whether you’re facing a complex design challenge or need advice on technical aspects, I’m here to ensure your project is a success from start to finish.

team member nathan

Nathan Jensen

Purchasing Manager – Nathan Jensen

Hi, I’m Nathan Jenson, the Purchasing Manager at WellPCB. I’m responsible for sourcing the best materials and components to ensure our products meet the highest quality standards. With my extensive experience in procurement, I work closely with suppliers to secure reliable and cost-effective solutions while maintaining strong relationships to support our operations. I aim to ensure every project runs smoothly by providing the resources needed to deliver on time and to your satisfaction.

team member emma

Emma

Sales Manager – Emma

Hey, I am Emma, sales manager at WellPCB. I studied electronic science and technology at university and have served customers for PCB and PCB Assembly service for several years.

I enjoy communicating with customers and our technicians to solve problems, and customers always say, "It's great to have you onboard".

It is my pleasure and honour to be helpful. Contact me now, and you'll know.

team member bella and cassiel

Bella and Cassiel

Sales Representatives – Bella and Cassiel

We’re Bella and Cassiel, your dedicated sales representatives at WellPCB. With our extensive knowledge of the PCB industry, we’re here to provide exceptional service and support. We take the time to understand your unique needs and are always ready to offer tailored solutions and advice. Whether you need product recommendations, assistance with your orders, or simply have a question, we’re here to ensure your experience is smooth and seamless at every step.

team member mandy and wendy

Mandy and Wendy

Sales Representatives – Mandy and Wendy

We’re Mandy and Wendy, your friendly sales representatives at WellPCB. Passionate about helping our customers, we bring a wealth of experience in the PCB industry to provide you with the best solutions and service. We take pride in building strong relationships with our clients, understanding their specific needs, and offering personalised support to ensure their satisfaction. Whether you’re looking for advice, product information, or assistance with any part of your order, we’re here to make your experience as smooth and efficient as possible.

Our Team

Our skilled engineers and technicians bring expertise and precision to every PCB assembly project. Committed to quality, efficiency, and innovation, our team ensures every order meets the highest UL, IPC, ROHS & REACH standards, delivering reliable solutions tailored to your needs.

  • Founder and Chief Editor – Hommer Zhao
  • Technical Manager – Jesse Holland
  • Purchasing Manager – Nathan Jensen
  • Sales Manager – Emma
  • Sales Representatives – Bella and Cassiel
  • Sales Representatives – Mandy and Wendy

All Wire Harness Services

Wiring Harness for Car Case Studies
integrated wiring harness assembly for sanitation vehicles

Wiring Harness

Integrated wiring harness assemblies streamline power and signal distribution in sanitation vehicles, offering robust performance in harsh outdoor and washdown environments.

automobile wire harness

Wiring Harness

Connects engine, dashboard, lights, A/C, audio, airbags, and more—forming a reliable, complete electrical system for vehicle performance and safety.

worker,is,packing,a,wiring,harnesses,,production,line,,workflow.,automobile

PCB Assembly

Used in autonomous driving systems, infotainment, and advanced vehicle electronics, our cable assemblies ensure fast, stable signal and power transmission under demanding conditions.

Client Feedback On Our Automotive Wiring Harnesses

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star rating 1

As an R&D manager, I have had an outstanding experience working with WELL-PCB. For many years, our company has entrusted them with the production, assembly, and programming of the boards developed in our R&D unit, and they have consistently exceeded our expectations.

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Hamid Reza Moshayedi

R&D Manager

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star rating 1

Their work is very impressively perfect. Today, when they check our company PCB board after assemble. They found a fake short point which many engineers has never found in the past years. But that is just designed so. The PCB board quality is excellent. Their service is also excellent.

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MikeZ

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star rating 1

My friend introduced WellPCB to me, the first try, a little look forward to. I ordered a 47*72 10ps PCB, and I can’t wait to receive my PCB. So I used expedited service and received my PCB in three days. I tested and soldered the PCB, Quality is really good, silkscreen, plating also great.

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Warren Cliton

Automotive Wiring Harness FAQs

We offer IATF 16949:2016, ISO 9001:2015, UL, and ROHS-certified flame-retardant insulation for interior harness applications.

Yes, we support CAN bus wiring if it’s clearly indicated on the provided customer drawings. This includes EMI shielding, including twisted pair layout, foil wrap, and defined shield termination paths.

We apply high-voltage DC between conductors and shielding to verify insulation performance and detect breakdown or leakage. This test is typically performed up to 1500 VDC, depending on the harness specification, and confirms compliance with required dielectric strength before release to final product manufacturing.

Yes, we offer high-temperature wire and cable with XLPE, silicone, or fiberglass jackets rated up to 150 °C for routing near engine and exhaust components.