Train Wire Harness Solutions
for Modern Rail Systems
WellPCB delivers durable wire harnesses for locomotives, passenger cars and mass transit applications.
Our harnesses are built to withstand vibration, harsh environmental conditions and complex electrical wiring needs.
From prototyping to full scale harness production, we provide tailored designs with a commitment to quality and long term reliability.
- Custom wire harnesses for rail and locomotive wire harness projects
- Certified harness assembly with ISO 9001, IPC/WHMA-A-620 compliance
- Fast turnaround and scalable harness manufacturing for the railway industry
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Train Wire Harness Manufacturing for Rail Vehicles
Train wire harnesses provide secure routing of electrical wiring, power and control signals across traction systems, braking modules and passenger comfort systems. They are fundamental to both high speed rail and mass transit networks, ensuring safe and reliable performance.
As the railway industry adopts new technologies for automation, signaling and energy efficiency, WellPCB supports this shift with wire harness manufacturing tailored to ISO 9001, IPC/WHMA-A-620 and IATF 16949 quality standards.
WellPCB manufactures train wire harnesses using flame-retardant XLPE or silicone-insulated cable and shielded conductors for EMI protection.
Every rail and locomotive wire harness undergoes 100% continuity testing, hi-pot verification up to 3 kV AC and pull-force validation of terminals. We tailor each one to specific needs of the rail industry, reducing installation time while maintaining long-term reliability in harsh environmental conditions such as dust, temperature cycling and outdoor weather conditions.
Our Train Wire Harness Capabilities
WellPCB produces traction wire harnesses rated for 600 to 1500V DC and 25kV AC railway networks.
Insulation systems are validated with conductor cross sections up to 120 mm².
These harnesses are built to withstand thermal cycling and long term load stresses in locomotive propulsion and braking circuits.
Control harness assembly includes shielded twisted-pair and multi-core looms for safe routing of signaling, monitoring and safety circuits.
EMI shielding is verified through impedance checks, reducing interference across sensitive electronic modules in rail vehicles and mass transit systems.
We manufacture harnesses for rail communication systems, including Ethernet Cat6, CAN bus and Multifunction Vehicle Bus (MVB).
Terminations are crimp-force validated and tested for continuity to improve signal systems across onboard control networks.
Our harness cables meet UL 94V-0 safety standards. Materials include XLPE, silicone and halogen-free insulation, delivering durability against harsh environmental conditions, outdoor weather conditions and tunnel environmental conditions common in the rail industry.
Our train wire harnesses integrate circular, rectangular and multi-pin connectors from TE Connectivity, Molex, Harting and Amphenol.
For long-term fleet upgrades, we can source specialized cables from Sumitomo Electric and Proterial Ltd., trusted global suppliers for railway electrification.
Harnesses are tailored to interface seamlessly with OEM systems from Siemens Mobility, Alstom and Hitachi Rail, supporting both new builds and modernization programs.
Overmolded backshells and sealed housings maintain electrical reliability under vibration, shock and fluctuating temperature ranges from -40°C to +125°C.
Injection-molded junctions and strain reliefs prevent cable fatigue in high motion areas.
These electrical components are qualified for use in both high-speed rail and heavy freight locomotive harness production, maintaining flexibility without compromising long term strength.
WellPCB supports prototyping of custom wire designs for new vehicle model development, delivering tailored harnesses within 3 weeks.
Small batch runs are scaled to customer-specific needs with automation-supported production lines to validate layouts before mass release.
Every train wire harness undergoes 100% electrical testing: continuity, insulation resistance above 1000 MΩ and hi-pot withstand testing up to 3 kV.
Mechanical pull-force validation ensures crimp integrity, demonstrating our commitment to quality for long term transportation safety and reliability.
Why Choose WellPCB?
One-Stop Service
Quality Assurance
Engineering Expertise
Global Reach
Fast Turnaround
Responsive Support
Where are Train Wire Harnesses Used?
Traction Systems
Control & Safety Systems
Passenger Comfort Systems
Freight Rail & Metro
What Standards Do Train Harnesses Comply With?
Quality Management
Fire Safety & Materials
Electrical Testing
Connector & Sealing Standards
Regional & OEM Standards
US Railway Standards
How We Manufacture Train Wire Harnesses
Step 1: Wire & Connector Selection
Step 2: Cutting, Stripping & Crimping
Step 3: Bundling & Overmolding
Step 4: Electrical & Mechanical Testing
Step 5: Packaging & Delivery
How to Order Your Train 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
Train Wire Harness Case Studies
PCB Assembly
This case study showcases a high-performance solar panel wiring harness for outdoor photovoltaic systems, requiring high and low temperature resistance, UV resistance, and efficient electrical conductivity.
We select high-quality, weather-resistant cables, precisely process terminals and connectors, and rigorously control insulation and sealing processes. This product can stably transmit power even in extreme environments, enabling efficient power generation in photovoltaic systems and fully demonstrates our expertise in solar panel wiring harness and photovoltaic cable manufacturing.
PCB Assembly
This project shows a solar wire harness specifically designed for DC combiner boxes in photovoltaic systems. The harness integrates multiple input strings from solar panels and safely channels the combined current toward the inverter.
High Current Capacity: Built with thick, tinned copper conductors to handle the combined output of multiple PV strings without overheating.
Safety and Protection: Incorporates fuse holders and ring terminals for secure grounding, reducing the risk of short circuits and electrical faults.
Easy Installation: Pre-terminated connectors allow for quick assembly on-site, lowering labor costs and installation time.
PCB Assembly
This case study highlights a customized wire harness developed for solar tracking systems that adjust panel angles throughout the day. The harness carries both control signals and power, ensuring the motorized trackers operate smoothly in outdoor environments.
Advantages:
- •Uses UV-resistant, flexible cables that withstand constant movement and bending without damage.
- •Multi-core design keeps power and data transmission reliable, even under continuous rotation.
- •Robust insulation and sealed connectors provide protection against dust, moisture, and temperature fluctuations.
Train 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
Train Wire Harness FAQs
What is the service life of train wire harnesses, and how are they maintained?
WellPCB’s harnesses are engineered for a 15 to 25 year service life, depending on operating duty cycles and installation environments. Preventive maintenance includes scheduled inspections for insulation wear, connector reseating and verification of continuity across safety circuits.
Can you supply both low-voltage and high-voltage harnesses?
Yes, WellPCB builds low-voltage wire harnesses for control, lighting and safety systems, as well as high voltage assemblies rated up to 25 kV AC and 1500 V DC for traction and auxiliary drives.
Can a train wire harness be customized for specific needs of different rail vehicles?
Yes, we can customize every harness to the operating requirements of the vehicle they’re being manufactured for by matching them exactly to the specs in the technical drawings. This includes conductor sizing, connector selection, shielding levels and overmolding. By customizing wire harness needs, operators receive assemblies optimized for space constraints, electrical load and mechanical durability in diverse rail vehicles.
How do you improve signal systems through harness design and integration?
WellPCB supports operators looking to improve signal systems by integrating shielded communication cables, low-loss conductors and validated grounding paths into the harness. Using Ethernet, CAN and MVB wiring structures, we reduce EMI and maintain signal clarity across long trainsets. This ensures accurate data transfer in transportation environments where reliable communication is critical.
We Deliver Train Wire Harness Products for All Railway Wiring Systems
Get $100 Off Your First Order!
Partner with WellPCB for train wire harness solutions built to meet global rail industry standards. We deliver certified assemblies that withstand harsh environmental conditions and keep your transportation systems running reliably.
