Rugged Waterproof Wire Harness
Solutions for Extreme Environments
Built for long-lasting performance in harsh and wet conditions, WellPCB’s waterproof wire harness systems maintain reliable electrical connections even under heavy vibration, salt spray and temperature swings.
Each wire, connector and seal is manufactured to meet IP67 waterproofing requirements, preventing moisture and dust from reaching sensitive circuits in automotive, marine and industrial equipment.
- Certified manufacturing under ISO 9001, IATF 16949 and IPC/WHMA-A-620 Class 3
- Corrosion-resistant tinned-copper conductors and UV-stable cable jackets for outdoor durability
- 100% electrical continuity and insulation resistance testing performed on every finished harness
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Waterproof Wire Harness Manufacturing Services
The North American wire harness market reached $22.63 billion in 2022, with waterproof assemblies being the fastest-growing segment driven by EV adoption and marine applications. Among 830+ US suppliers, WellPCB’s factory-direct manufacturing in Shenzhen and Jiangmen delivers 2 to 3 week prototype turnaround versus the industry standard 8 to 12 weeks.
WellPCB provides complete waterproof wire harness manufacturing for demanding environments where reliability can’t fail. Each wire, connector and seal is produced in controlled conditions using automated crimping, over-molding and inspection systems. Our team delivers consistent quality for automotive, marine and industrial wiring assemblies that perform under extreme conditions.
Our production capabilities include precision wire cutting and stripping, insertion of IP-rated waterproof connectors and application of adhesive heat shrink tubing for secure sealing.
Using tinned-copper conductors, silicone or PVC insulation and UV-resistant cable jackets, we build custom waterproof harness assemblies designed to resist corrosion and water ingress. All finished assemblies undergo dielectric, continuity and insulation resistance testing before packaging.
Our Waterproof Wire Harness Capabilities
Automated wire cutting, stripping and crimp operations achieve strict precision on every wire and terminal.
Each wire harness is built on controlled tooling with digital crimp-force monitoring and pull testing. This accuracy supports stable electrical connections for automotive, marine and industrial assemblies exposed to vibration or water.
Every connector and junction is protected through thermoplastic or epoxy over-molding, forming a single-piece waterproof wire loom.
Adhesive-lined heat shrink tubing and molded strain reliefs prevent water from entering joints while absorbing flex and mechanical stress during installation.
WellPCB assembles IP-rated sealed connectors from TE Connectivity, Molex and Amphenol (to name a few), integrating O-ring seals and compression fittings into every plug, socket or pigtail configuration.
These waterproof connectors maintain reliable continuity and resist corrosion in outdoor applications and marine-grade environments.
Every waterproof wire harness is tested for continuity, insulation resistance and dielectric resistance up to 1000 V DC.
Additional validation includes temperature cycling from –40 °C to +125 °C, salt-spray corrosion testing and hydrostatic submersion for IP67 compliance. These controls guarantee dependable performance in extreme conditions.
Harnesses use tinned-copper conductors with silicone, XLPE or PVC insulation for flexibility, UV resistance and anti-corrosion protection.
Dual-layer cable jackets, gaskets and grommets add resistance against moisture and dust, while each joint is sealed with approved electrical tape or potting compound.
Production follows ISO 9001, IATF 16949 and IPC/WHMA-A-620 Class 3 certification. Every assembly meets global quality and compatibility requirements for industrial and automotive harness production.
Documented process control and batch traceability maintain reliability from prototype to shipment.
Low-volume builds are available in 2 to 3 weeks, with full production orders typically delivered in 4 to 6 weeks.
Semi-automated lines accommodate both small prototype runs and large-scale cable assembly batches without compromising quality or precision.
Each finished harness undergoes 100% electrical inspection, visual quality review and mechanical verification.
Full reports include test data, part labeling and material certifications to support compliance audits and long-term maintenance records.
Why Choose WellPCB to Manufacture Your Waterproof Wire Harness?
Factory-Direct Manufacturing
Unlike many resellers, we own our production facilities in Shenzhen and Jiangmen, giving us full control over quality, cost and delivery timelines.
IPC Class 3 Quality Assurance
All waterproof harnesses meet the highest reliability classification for environments such as automotive, marine and defense systems.
Certified Global Standards
Manufacturing processes align with standard compliances to guarantee consistent output for global OEM supply chains.
End-to-End Production & Testing
From wire processing to overmolding and IP validation, every stage is performed in-house under documented quality control procedures so there’s no outsourcing or quality risk.
Rapid Turnaround & Flexible Orders
Prototypes ship within 2 to 3 weeks and production within 4 to 6 weeks, enabling faster time-to-market without MOQ restrictions (unlike most companies’ 8 to 12 weeks).
Proven Reliability in Extreme Environments
Our waterproof wire harnesses operate for 15 to 25 years in service, maintaining electrical stability under continuous exposure to vibration, temperature shifts and moisture.
Applications of Waterproof Wire Harnesses
WellPCB’s waterproof wire harness solutions support reliable power and signal transmission across industries where water exposure, vibration and temperature changes threaten system stability. Each harness uses IP-rated sealed connectors, precision-crimped terminals and over-molded joints to deliver long-lasting performance in high-moisture and dustproof environments.
Automotive & EV Systems
Marine & Offshore
Industrial Equipment
Renewable Energy Systems
Materials Used In Waterproof Wire Harnesses
Each waterproof wire harness manufactured by WellPCB is built from durable, field-proven materials selected for mechanical strength, corrosion resistance and electrical reliability. From precision-tinned wires to sealed over-molded housings, every component contributes to long-term connectivity and system integrity in extreme conditions.
Conductors and Wire Gauge
Insulation and Protective Jackets
Overmolded and Strain-Relief Components
Sealing Compounds and Water-Blocking Materials
Testing and Validation Standards
Every waterproof wire harness produced by WellPCB is verified through rigorous electrical, mechanical and environmental testing to guarantee long-lasting performance in high-stress environments. Testing ensures every wire, connector and seal maintains structural integrity and electrical continuity even after prolonged water exposure and vibration.
Electrical Tests
All assemblies undergo 100% continuity inspection, dielectric resistance, and insulation resistance verification.
Each circuit must achieve ≥ 100 MΩ @ 1000 V DC and contact resistance ≤ 10 mΩ, confirming complete protection against moisture and dust ingress.
These tests validate electrical connectors and terminals for both signal and power transfer under load.
Mechanical Tests
Mechanical evaluations include pull-out force measurement, vibration testing from 10 to 500 Hz, and flex-bend cycles simulating operational stress.
These trials verify the reliability of IP-rated connectors, wire crimps and harness clamps used in field assemblies, ensuring mechanical integrity and protection against conductor fatigue or seal rupture.
Environmental Tests
Environmental validation replicates extreme conditions through 30 minute immersion at 1 m depth and salt-spray exposure exceeding 500 hours (ASTM B117).
Heat shrink seals, O-rings and gaskets are examined for leakage and corrosion resistance.
These tests confirm that WellPCB’s waterproof harnesses remain fully functional even after repetitive submersion or high-humidity cycles.
Technical Specs of Waterproof Wire Harnesses
| Parameter | Specification | Why It Matters |
|---|---|---|
| Voltage Rating | 12 V to 1000 V | Covers automotive, EV, and industrial power ranges |
| Current Capacity | Up to 240 A peak | Supports heavy-duty power circuits in industrial and marine systems. |
| Operating Temperature | –40 °C to 125 °C | Ensures performance in extreme heat and cold |
| Wire Gauge | 16 to 24 AWG | Balances flexibility and current-carrying capacity |
| Insulation Resistance | ≥ 100 MΩ @ 1000 V DC | Guarantees moisture isolation |
| Salt Spray Resistance | 500+ hrs (ASTM B117) | Ensures corrosion-free operation in marine installations |
| Conductor Material | Tinned copper | Corrosion-resistant for marine/industrial use |
| Overmolding Material | TPU / Epoxy | Provides long-term waterproof sealing |
| Connector Type | Threaded / O-ring / Compression | Maintains IP protection after repeated mating |
| IP69K Rating | High-pressure water jet resistance | Required for FDA-compliant food and pharma washdown applications |
How to Order Your Waterproof 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
Waterproof 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.
Waterproof 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
Waterproof Wire Harness FAQs
How do you waterproof a wiring harness during manufacturing?
Each waterproof wire harness is sealed using over-molding, adhesive-lined heat shrink and compression fittings around every connector and joint. Layers of tubing, gels and O-rings block water from entering the wire loom. These construction methods maintain protection against moisture and dust in high-humidity environments.
Can WellPCB build harnesses for appliance or controller systems?
Yes, WellPCB manufactures custom waterproof harnesses for electronic appliances and controller assemblies that require compact wire connectors and stable electrical wiring. Each harness is tested for continuity and insulation performance to meet safety and certification requirements.
What maintenance steps extend the life of a waterproof harness?
To maintain long-lasting performance, inspect all connectors, pins and sockets for corrosion or wear. Apply dielectric grease on electrical connectors, secure clamps and bulkhead fittings and replace damaged gaskets or heat shrink tubing as needed. This prevents oxidation and keeps circuits safe from water.
Are waterproof wire looms compatible with standard electrical systems?
Yes, each waterproof wire loom is designed for full compatibility with standard cable assemblies and electrical wires used in industrial, automotive and marine-grade systems. Using tinned conductors, cable jackets and sealed termination methods ensures consistent connectivity across different electronic wiring enclosures.
What standards govern the testing and safety of waterproof wire harnesses?
WellPCB’s waterproof wire harnesses are tested and manufactured according to internationally recognized standards. IEC 60529 defines the IP67, IP68 and IP69K waterproof classifications that specify protection against moisture and dust ingress.
Corrosion resistance is verified through ASTM B117 salt-spray testing, which measures performance after 500+ hours of exposure in marine-grade environments. All connectors, cables, and insulation materials comply with UL and CENELEC safety frameworks to guarantee long-term electrical reliability and material integrity in global applications.
How do I choose the right IP rating?
Selecting the correct IP rating depends on exposure conditions: IP67 for temporary immersion, IP68 for continuous submersion and IP69K for high-pressure washdown or sanitization. For outdoor applications or renewable energy systems, IP68 and IP69K-rated waterproof wire looms are strongly recommended.
Get Reliable Waterproof Wiring Built to Last
Get $100 Off Your First Order!
Order your waterproof wire harness directly from WellPCB for tested durability and IP-rated protection. Every connector, wire and seal is built for heavy-duty performance.
