Fast, Reliable, No MOQ
Prototype Wire Harness Services
When your product timeline can’t handle a 12-week delay or a $100,000 tooling change, you need a prototype wire harness supplier who can validate fit and function as fast as possible.
WellPCB’s prototype wire harness services deliver precise, tested and production-ready prototypes for any industry.
We combine IPC/WHMA-A-620 Class 3 workmanship, UL-listed components and rapid prototyping technology to shorten your development cycle while maintaining aerospace-grade reliability.
- Built to UL and IPC/WHMA-A-620E Class 3 standards
- 100% tested assemblies with Hi-Pot, continuity and pull testing
- Lead times as short as 2 weeks with full documentation and compliance
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ISO9001 ISO13485
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IPC-A-610H International
Certification
Fully Automated
AOI Inspection
What is a Prototype Wire Harness?
A prototype wire harness is a pre-production wiring solution used to validate electrical routing, connector choices and layout under real-world load conditions. These assemblies help manufacturers confirm functional fit and electrical integrity before moving to mass production.
Each wire harness prototype undergoes rigorous testing to make sure it meets performance and safety benchmarks before scaling to mass production.
At WellPCB, we support full harness prototype design and manufacturing, from concept checks to production-ready assembly prototypes. We build to your exact requirements using high-reliability wire, standardized connector types and industry-compliant insulation and routing practices.
Our Prototype Wire Harness Capabilities
We offer fast lead times of 2 to 3 weeks for standard prototypes, compared to the typical 8 to 12 weeks offered by others. That’s fast enough to complete 3 to 5 design iterations in the time competitors deliver a single prototype.
We support connector families across Molex Mini-Fit Jr, TE AMPseal, JST XH, Deutsch DT and others. Terminal selection is based on mating cycles, current load and housing compatibility with your enclosure or PCB system.
Our testing includes automated continuity, Hi-Pot, load/current and pull testing per industry standards. Data logging provides full traceability and certificates of compliance.
Our engineers use innovative 3D-printed test jigs and fixtures, which can reduce lead time by 50 to 70% compared to CNC tooling, giving you faster design iterations.
Ultrasonic splice welds improve joint strength and reduce electrical resistance while maintaining consistent crimp height analysis through automated CFA systems.
Each prototype includes serialized labels, test reports and digital traceability for future production reference.
Why Choose WellPCB for Your Prototype Wire Harness?
One-Stop Manufacturing
Full in-house support for wire cutting, strip, crimp, soldering, testing and labeling in one streamlined workflow at our Shenzhen and Shijiazhuang facilities.
Certified Quality Systems
High-Speed Prototyping
Standard prototype wire harness delivery in 2 to 3 weeks, so you can iterate fast and get to market. Compared to 8 to 12 weeks from other manufacturers, you’ll be ahead of the game.
No MOQ
Start with just one unit. Ideal for low volume, small batch or engineering validation builds.
Scalable Production
Seamlessly scale from prototype assemblies to mass production without switching suppliers or specs.
Global Delivery Network
Rapid logistics across North America, Oceania and Europe with support for custom lengths and import documentation.
Technical Specifications for Prototype Wire Harnesses
Every prototype wire harness we manufacture meets strict performance, safety and compliance benchmarks while being tailored to your project requirements and application.
| Parameter | Specification | Why It Matters |
|---|---|---|
| Wire Gauge Range | 10 to 30 AWG | Supports a wide range of signal and power applications in compact harness builds. |
| Voltage Rating | Up to 600 V AC/DC | Suitable for both low-voltage logic and higher power automotive/industrial loads. |
| Temperature Range | 80 °C to 105 °C | Matches insulation specs for most automotive, aerospace, and medical uses. |
| UL Wire Styles | UL 1007, 1061, 1569, 1015 | Ensures compatibility with UL-recognized components and US safety expectations. |
| Mating Cycles | 500+ | Allows repeated connection/disconnection during prototyping and validation. |
| Testing Methods | Continuity, Hi-Pot, Load, Pull, Abrasion | Verifies electrical integrity and physical durability before production scale-up. |
| Connector Types | Molex, JST, TE Connectivity, Deutsch, Amphenol | Supports a wide range of standard interfaces across industry applications. |
| Shielding Options | Foil / braid / EMI sleeving | Protects against signal interference and meets EMC design requirements. |
| Harness Length | Up to 5 m (custom) | Accommodates both compact and large-frame equipment assemblies. |
| Documentation | Certificate of Compliance, Test Report, Serial Tracking | Enables full traceability and validation throughout the design process. |
Our Prototype Wire Harness Manufacturing Process
We review all client schematics, CAD drawings or sketches and apply DFM (Design for Manufacturability) checks to optimize layout, reduce your costs and align your project with harness assembly standards.
We select UL-listed wire (eg. UL 1007, 1015) and compatible connector types like JST, TE or Amphenol based on current ratings, insulation and routing needs.
High-precision automated equipment helps us achieve exceptional accuracy on wire lengths and insulation strip depth for consistent crimp integrity.
Our engineers crimp each terminal using calibrated presses and validated against pull-force charts. Select joints are hand-soldered to IPC Class 3 standards for reliability.
We use custom fixture boards or 3D-printed jigs to control complex routing paths, maintain repeatability and meet your exact harness dimensions.
Each prototype wire harness undergoes continuity, Hi-Pot and optional load testing, with test data logged and traceable through serial numbers and certificates of compliance.
All harnesses are labeled, serialized and shipped in custom protective packaging, ready for integration, inspection or functional testing.
IPC/WHMA-A-620 Class 3 Testing Methods
Each prototype wire harness undergoes testing procedures that align with Class 3 workmanship standards, ensuring long-term reliability in their specific applications.
Hi-Pot Testing
Verifies insulation breakdown voltage under high potential. Prevents shorting, arcing and insulation failure during overload.
Pull Testing
Measures crimp retention force using motorized pull testers. Ensures connector retention during vibration or tension.
Continuity Testing
Validates open/short circuits using CableScan systems. Can test 100+ interconnects in seconds.
Abrasion & Aging
Follows ISO 6722 stroke testing and Ford 3,000-hour thermal aging methods to predict long-term field wear.
Industries We Serve with Prototype Wire Harnesses
WellPCB supports diverse industries with custom wire harness solutions that meet stringent regulatory, environmental and performance standards.
Aerospace
Built to industry standards, our harnesses support flight and satellite subsystem applications with high-temperature insulation, EMI shielding and 100% verified electrical paths.
Automotive
Wire harness prototypes for EV powertrains, ADAS sensor suites, interior modules and more. Designs include support for complex routing, and use automotive-grade terminals and connectors.
Medical
Harnesses for surgical equipment, imaging devices, and diagnostic tools using biocompatible materials, sterile-ready cable assemblies and redundant crimp and solder joints for maximum fault tolerance.
Industrial Equipment
Designed for robotics, motion control, HVAC and automation systems. Features include rugged cable jacketing, load-rated connector types and application-specific testing phases for industrial applications.
Consumer Electronics
Small-batch, high-density prototype cable assemblies for wearables, smart home devices and IoT systems. They’re optimized for low-volume production, compact routing and exact specifications.
OEMs & R&D Labs
Ideal for early-stage product development, customization and evaluation testing. We offer engineering support, rapid build cycles and scalable transfer from prototyping services to production.
Emerging Technologies in Wire Harness Prototyping
Across the wire harness industry, advanced technologies are reshaping how engineers manufacture prototype assemblies with greater accuracy, speed and scalability. These innovations support custom wiring, shorten timelines and improve consistency from design to validation.
Cloud Design
Automation
Automated equipment handles wire cutting, stripping, crimp monitoring and continuity testing with minimal operator input. This improves precision and supports low-volume production with tighter tolerances.
Industry 4.0 Integration
Digital dashboards and MES systems provide traceability, track defects and log testing phases, enabling real-time quality control and process improvement for each harness prototype.
Additive Manufacturing
3D-printed fixtures are used to hold wires and connectors during assembly, improving accuracy for complex routing and reducing tooling lead times in fast-paced prototyping services.
How to Order Your Prototype Wire Harness
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
Prototype Wire Harness Case Studies
PCB Assembly
The picture shows an HDMI-to-DVI cable with USB power. It can be used to connect HDMI-enabled devices (such as laptops and TV boxes) to DVI-equipped monitors and other home appliances.
Advantages:
- •Strong Compatibility: Allows connection between devices with different interface standards, expanding their use cases.
- •Stable Transmission: Provides stable video signal transmission, minimizing interference and loss during signal transmission.
- •Convenient Power Supply: No need to find a separate power source, making it more convenient to use.
PCB Assembly
The picture shows an HDMI-to-DVI cable with USB power. It can be used to connect HDMI-enabled devices (such as laptops and TV boxes) to DVI-equipped monitors and other home appliances.
Advantages:
- •Strong Compatibility: Allows connection between devices with different interface standards, expanding their use cases.
- •Stable Transmission: Provides stable video signal transmission, minimizing interference and loss during signal transmission.
- •Convenient Power Supply: No need to find a separate power source, making it more convenient to use.
PCB Assembly
The picture shows an HDMI-to-DVI cable with USB power. It can be used to connect HDMI-enabled devices (such as laptops and TV boxes) to DVI-equipped monitors and other home appliances.
Advantages:
- •Strong Compatibility: Allows connection between devices with different interface standards, expanding their use cases.
- •Stable Transmission: Provides stable video signal transmission, minimizing interference and loss during signal transmission.
- •Convenient Power Supply: No need to find a separate power source, making it more convenient to use.
Prototype Wire 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
Prototype Wire Harness FAQs
Why is prototyping important?
Prototyping helps identify design flaws, verify electrical performance and confirm fit before committing to production. It reduces costly rework, speeds up development, and improves product reliability. The average cost of a prototype wire harness order is $500 to $2,000, worth it to avoid field failures of $100,000 or more.
How is a wire harness prototype different from a cable assembly prototype?
A wire harness prototype organizes discrete wires using sleeving or tape for internal routing, while prototype cable assemblies involve jacketed cables with EMI shielding and molded backshells. Both serve different mechanical and environmental needs.
What documents must I submit for a quote?
We need a wiring diagram or schematic, connector list or BOM, estimated harness length and quantity required. Photos or reference samples can also help with quoting accuracy.
What is IPC/WHMA-A-620 Class 3 certification?
It’s the highest standard for wire harness quality, covering critical-use products like aerospace, medical and defense systems. Class 3 requires full inspection, tight tolerances and zero defect acceptance.
Class 1 covers general electronic products, like consumer electronics where basic functionality is primary requirement. It accepts minor cosmetic variations that don’t affect performance.
Class 2 is for dedicated service electronics, which covers commercial products requiring extended service life and reliability. It has stricter workmanship tolerances than Class 1.
Class 3 is WellPCB’s standard. It’s for high-reliability / life-safety electronics, covering applications that require zero-defect acceptance. It requires a 100% inspection protocol, complete documentation traceability and has exceptionally tight tolerances for things like crimp quality, insulation and solder joints.
How does prototype harness testing differ from production harness testing?
Prototype assemblies may include additional or temporary features like test headers or extra breakouts for easier diagnostics during R&D. Final production units are typically streamlined for durability and cost.
Can I request a specific brand of connector or terminal for my prototype wire harness?
Yes, you can specify brands such as Molex, JST or Amphenol, and we’ll source compatible parts based on your project requirements, stock availability and component selection preferences.
No MOQ Prototype Wire Harness Manufacturing
Get $100 Off Your First Order!
Ready to move fast on your next prototype wire harness? Whether you’re validating a new design or preparing for small-batch production, we deliver high-precision builds with no minimum order and full electrical testing included.
