Custom Marine Wiring Harnesses
for Boats, Offshore, and Subsea Systems
Marine wiring harnesses transmit electrical signals and power between marine electronics, propulsion systems, and onboard electrical systems in saltwater environments.
WellPCB builds custom marine wire harnesses using tinned copper marine boat wire, sealed waterproof connectors, and jacketed cable assemblies engineered for high-flex, high vibration, and corrosion prone conditions.
As a marine wire harness manufacturer, we manufacture halogen free, flame retardant products compliant with IEC 60092 and BS6883 standards.
- Custom tinned copper assemblies with waterproof sealing.
- Fast prototype-to-production turnaround with testing reports.
- Manufactured to IEC 60092 and BS6883 standards.
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Marine Wire Harness Manufacturer for Vessel-Wide Integration
Each wire harness is engineered for electrical distribution in wet, vibration prone zones across boat hulls, decks, and subsea enclosures. Jacketed marine boat wire with thermoplastic or XLPE insulation maintains conductor stability across wide temperature shifts, chemical exposure and mechanical flex.
Multi-conductor assemblies are terminated with marine grade grommets, pass-through seals and ganged cable connectors rated for long term open-environment use.
WellPCB supplies harness solutions for shipboard lighting control, motor actuation, sensor telemetry, and auxiliary power systems.
Routing constraints, conductor lengths, and wire harness requirements are defined per application to minimize EMI, thermal rise and current loss.
Circuit separation and grounding paths are specified to isolate analog signals from propulsion and winch loads in marine electrical zones.
Our Marine Wire Harness Capabilities
WellPCB provides wire harness manufacturing solutions for marine platforms requiring sealed terminations, thermal insulation and certified conductor routing.
Our capabilities include connector integration, cable jacket selection, circuit isolation and full test coverage. Every marine wiring harness is built to meet defined wire harness requirements for environmental stress, current load, and system performance.
WellPCB manufactures every marine wiring harness using UL-rated, stranded 16–4 AWG marine boat wire with tinned copper cores. Insulation is flame-resistant, thermoplastic, and rated to 221 °F (105 °C) continuous.
Strand counts exceed 26 per conductor to reduce EMI and improve flexibility under vibration. All wire ends are stripped to tight tolerances and optionally pre-tinned.
IP67/IP68-rated connectors are applied to all boat wiring harness builds. Termination processes include grommeted entry points, sealed housings, and thermoplastic molding for water exclusion and strain relief.
Test cycles verify seal compression, pull resistance, and conductivity. Connector part IDs and sealing classes are tracked by our internal wire harness manufacturing system and matched to the specific requirements of each customer design.
WellPCB applies jackets based on routing and exposure zones. Cable assemblies use UV-resistant PVC, XLPE or multi-conductor cable with abrasion-rated outer wraps.
Braided sleeving or high temp silica layers are used in engine spaces or bilge zones. Each jacket type is selected to meet industry standards for chemical resistance, thermal limits, and mechanical flex. All materials conform to the relevant quality standards.
Each marine wire harness supports mixed AC/DC routing, CAN bus, GPS, and NMEA 2000. We isolate high voltage lines from signal paths using shielded multi-conductor bundles and twisted-pair layouts.
Voltage drop and impedance are controlled in accordance with recommendations. These builds serve OEMs that require performance and safety across both digital and power branches. All routing aligns with the defined electrical systems architecture for the vessel class.
Our technicians complete every custom wire harness on printed layout boards with BOM-driven routing and labeled tie-downs.
Crimping and stripping follow strict tolerance windows, and staging is documented per lot. All assembly is logged and scanned for duplication across builds.
Each form board is reviewed for compatibility with panel production and connector alignment. This supports precise repeatability in high-mix assembly services.
Testing includes IR, hipot, and continuity checks across all wire harness assembly outputs. Salt spray chambers validate corrosion tolerance to ASTM B117.
Optional vibration and temperature cycling confirm endurance in harsh marine environments. All tests are documented under stringent quality control processes, including test reports that are matched to customer specifications.
Build certifications are archived for traceability and project audits in marine wire harness manufacturing workflows.
We validate all subsea marine wire harness builds to 1,000 PSI using hydrostatic chambers. Cable jackets and overmolds are inspected for compression failures, voids and microleaks.
Test plans are based on ROV or umbilical cable routing with depth simulation. Elastomer-jacketed cable and sealed connectors are rated according to your project specifications.
These validations are essential to ensure quality and reliability in subsea installations.
Why Choose WellPCB as Your
Marine Wire Harness Manufacturer?
WellPCB provides marine wire harness assemblies that meet UL and ISO9001 with application-matched routing, component selection and validation.
Our wire harness manufacturing process supports every custom wire harness with inspection records, sealed connectors, and schematics tailored for marine platforms exposed to heat, moisture and mechanical stress.
Certified to UL, ISO, and RoHS Standards
Marine Electronics Integration with PCB Assembly
Rapid Prototyping for Custom Vessels and Refits
Consistent Quality for OEM and Defense Platforms
End-to-End Manufacturing from Harness to Enclosure
Proven Experience in Subsea and Offshore Applications
Marine Wiring Harness Applications We Support
WellPCB builds application-specific marine wiring harness assemblies for propulsion, navigation, lighting, safety and submersible systems. Each design meets defined wire harness requirements for jacket type, voltage drop and circuit isolation across all marine applications, including onboard and subsea environments.
Control Panel Harnesses for Recreational Boats
Power and Navigation Harnesses for Commercial Ships
ROV Tether Cables with Subsea Sealing
LED, Radar, AIS, and NMEA 2000 Harness Systems
Bilge, Pump, and Safety Interconnect Harnesses
Offshore Winch and Crane Control Cabling
Engine, Ignition, and Propulsion System Looms
What is Our Marine Wiring Harness Manufacturing Process?
WellPCB builds every marine wire harness using a defined process sequence for compliance, accuracy and repeatability.
Each stage is scoped for traceability and aligned with target platform specifications. Our workflow supports OEM-aligned wire harness manufacturing, featuring serialized tracking, layout validation and output that matches schematic and panel production formats.
Design and Electrical Review
Material Selection and BOM Lockdown
Fixture-Based Assembly and Routing
Testing and Final Documentation
Submit Your Design
Send us your design details (Drawing or Detailed Specifications).
Get a Fast Quote
Once your design and specs are received, a fast quote will be sent to you within 24 hours.
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.
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.
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.
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!
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.
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.
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.
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.
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
Wire Harness
Marine wiring harnesses require abrasion, vibration, and water resistance. Our waterproof solutions ensure reliable performance in harsh, moisture-prone environments.
Specifications:
- •Voltage: Up to 600V
- •Temp Range: -40°C to +125°C
- •Conductor: Tinned copper (corrosion-resistant)
- •Insulation: Cross-linked Polyethylene (XLPE)
- •Sealing: IP67/IP68-rated connectors
- •Protection: Braided sleeving or heat-shrink tubing
- •Certifications: UL, ABYC, RoHS, ISO 8846
Wire Harness
Tinned Copper Marine Wire refers to a wire with a layer of tin plated on the surface of the copper wire. It is particularly suitable for ships and marine environments because of its excellent corrosion resistance and oxidation resistance.
Specifications:
- •Conductor: Stranded tinned copper
- •Voltage: Up to 600V
- •Temp Range: -40°C to +105°C
- •Insulation: PVC or XLPE (oil & flame resistant)
- •Corrosion Resistance: High (saltwater-rated)
- •Flexibility: High strand count for easy routing
- •Standards: UL 1426, ABYC, USCG, RoHS
PCB Assembly
Traceability documentation ensures every wire and harness meets quality, safety, and compliance standards—critical for marine, medical, and automotive applications.
Traceability Documentation:
- Strict assembly specifications
- Wire harness traceability
- Can provide shipping report and test report
Marine Wiring Harness Client Feedback
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.
Hamid Reza Moshayedi
R&D Manager
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.
MikeZ
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.
Warren Cliton
Marine Wiring Harness Manufacturer FAQs
What is marine wire harness manufacturing?
Marine wire harness manufacturing is the process of designing, routing, terminating, and testing wire assemblies built for use in boats, offshore platforms, and subsea systems. It includes selection of marine grade wire, sealed connectors, and environmental protection components to meet UL, ISO 9001:2015, IATF 16949 and RoHS standards.
What regulations do your marine harnesses meet?
Our marine wiring harnesses meet UL, ISO 9001, IATF 16949, and RoHS standards.
Do you offer pressure-tested underwater harnesses?
Yes, we build marine wiring harnesses for underwater systems that are pressure tested to 1,000 PSI using hydrostatic validation. These harnesses include IP68 connectors, elastomer jackets, and molded transitions for sealed subsea deployment.
What tests are included on your marine wire harnesses?
Each marine wire harness undergoes continuity, insulation resistance (IR), and high-potential (hipot) testing. Additional validations include ASTM B117 salt spray, mechanical vibration at 10 to 500 Hz and thermal cycling from –40 °F to 221 °F (–40 °C to 105 °C) when required by the project’s wire harness requirements.
How quickly can I get a prototype marine harness?
Prototype marine wiring harness orders ship within 2 to 3 weeks after layout and BOM approval. This includes schematic validation, material sourcing, and full functional testing. Expedited builds are available in 2 weeks for approved wire harness assembly projects with finalized routing and connector specs.
Chart Your Course with a Reliable Custom Marine Harness Manufacturer
Get $100 Off Your First Order!
Our certified technicians specialize in UL-rated assemblies with IP67/IP68 connectors and custom routing solutions. Whether you need prototype harnesses for vessel refits or production volume assemblies for OEM platforms, we deliver fully tested, documented solutions that meet ISO and IATF certification standards with RoHS-certified materials.
