Custom Wiring Harness Manufacturer
WellPCB is a full-service custom wiring harness manufacturer specializing in precision-built wiring harnesses and assemblies for automotive, aerospace, industrial, and consumer electronics applications.
- End-to-end custom wiring harness design, prototyping, and production from 1 to 10,000+ units.
- Wire and cable processing with precision cut-strip-crimp machines (±0.2 mm cut tolerance).
- Certified to ISO 9001:2015 and IPC/WHMA-A-620 Class 2 and Class 3 workmanship standards.
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
End-to-End Harness Assembly Services from Design to Testing
We deliver custom wiring harness assemblies for mission-critical applications in automotive, industrial, medical, robotics, and more. Our process covers everything from schematics and connector selection to assembly and 100% functional testing.
WellPCB supports both prototype and volume harness production using UL-listed components and automated wire processing equipment. Every assembly is validated with dimensional, continuity, and hi-pot testing. Whether you need a single high-reliability sample or 10,000 units, we ensure tight control, consistent quality, and fast turnaround.
Technical Capabilities & Specifications:
Our harness production capabilities support wire gauges from 4 AWG to 28 AWG, with options for PVC, Teflon, XLPE, and braided shielding jackets, and insulation rated up to 150°C. We manufacture custom wiring harnesses with multi-branch routing, overmolded junctions, EMI shielding, and waterproof sealing (IP67/IP68).
Wire and cable processing utilizes precision cut-strip-crimp machines with ±0.2 mm cut tolerance. All assemblies undergo 100% continuity and hi-pot testing, with production traceability supported by barcode serialization and in-line AOI.
Our Custom Wiring Harness Capabilities
We process a wide range of wire gauges (30 to 10 AWG) using precision CNC cutters with ±0.2 mm strip accuracy. Multiconductor and discrete wires are cut and stripped in-line for efficient harness production with tight dimensional tolerances.
Our automated wire harness assembly lines handle multi-color and multi-gauge wire bundles simultaneously. Servo-controlled feeders and inline rotary cutters support jacketed and single-core wires with optimized cycle times for large-scale harness builds.
We provide terminal crimping, ultrasonic splicing, and soldered terminations with tooling for JST, Molex, TE Connectivity, AMP, and Deutsch connectors. Crimp force monitoring ensures electrical and mechanical compliance with IPC/WHMA-A-620 Class 2 and 3 standards.
Harnesses are labeled with thermal-transfer or laser wire marking systems, supporting alphanumeric and barcode formats. Every wiring harness assembly can be serialized and tracked through barcode tagging for real-time traceability and QA documentation.
We apply flexible PVC, braided PET, or heat-shrink conduit sleeving across assemblies for abrasion, EMI, and moisture protection. Optional overmolding is available for junctions and strain relief using PVC or polyurethane injection-mold tools.
Our harnesses support flat ribbon and round cable formats, integrating multi-conductor structures (up to 50 cores) with custom spacing, pitch control, and strain-relief booting, ideal for display cables, control panels, and interconnect looms.
We use custom harness boards for controlled routing, coiling, and taping. Flat-wrap, spiral-wrap, and tape-wrapped bundles are formed per drawing, with positional accuracy of ±1 mm across all wiring harness assemblies.
Why Choose WellPCB as Your Custom Wiring Harness?
Certified, High-Reliability Builds
Engineering-Backed Customization
Global Component Sourcing
Scalable Production
Fast Lead Times
100% Functional Testing Included
Types of Custom Wiring Harnesses We Build
We manufacture various custom wiring harnesses engineered to meet the electrical, environmental, and mechanical demands of specialized applications across multiple industries.
Automotive Harnesses
Medical Device Leads
Robotics & Motion Control Harnesses
Consumer Electronics Wiring
Solar/Outdoor Harnesses
Industrial Equipment Harnesses
What Certifications and Compliance Does WellPCB Have?
WellPCB adheres to globally recognized quality, safety, and environmental standards to ensure every custom wiring harness we manufacture meets strict industry and customer requirements.
IPC/WHMA-A-620 Class 2 & Class 3
We build wiring harness assemblies to IPC/WHMA-A-620 standards, the industry benchmark for cable and wire harness acceptability.
Class 2 covers general electronics with consistent performance requirements, while Class 3 addresses high-performance systems like aerospace, medical, and defense, requiring maximum reliability.
ISO 9001 Certified
WellPCB is ISO 9001:2015 certified, ensuring a robust quality management system (QMS) across every production stage, from component sourcing and tooling setup to final testing and packaging.
Our QMS supports continuous improvement, traceable documentation, and customer-specific process control for custom wiring harness builds.
RoHS & REACH Compliance
All wiring harnesses are produced using materials that are compliant with RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorization of Chemicals) directives.
We avoid hazardous substances like lead, cadmium, and brominated flame retardants, supporting safe usage in consumer electronics, medical devices, and industrial controls.
UL Wiring Standards
We follow UL-recognized wire types and connector standards (e.g., UL1007, UL1015, UL2464) for safety-critical harness applications.
When required, we build to support UL-certified final assemblies, enabling our customers to meet UL product certification criteria more easily during system-level compliance testing.
IATF16949
For automotive harness programs, we align with IATF 16949 quality standards, emphasizing defect prevention, production part approval (PPAP) protocols, and process control across the manufacturing line.
While formal certification is pending, our harness workflows support documentation and performance traceability that are consistent with IATF expectations.
What Connectors & Components
Does WellPCB Support?
WellPCB supports a comprehensive range of wiring harness connectors, terminals, and integration options to meet diverse electrical, environmental, and mechanical requirements across industries.
Industry-Standard Connector Support
Terminal Types and Wire-End Options
Overmolding and Strain Relief Options
Mixed-Gauge and Mixed-Connector Harnesses
Technical Performance Options
| Technical Aspect | Options |
|---|---|
| Wire Gauge Range | 10 to 30 AWG |
| Temperature Rating | -40°C to 125°C (-40°F to 257°F) |
| Shielding | Braided, foil, ferrite bead support |
| IP Rating | IP65, IP67, IP68 capable |
| Flame Retardant Jacketing | UL VW-1, CSA FT-4 |
| Sheathing | UV, chemical, and abrasion-resistant |
How to Order Your Custom Wiring Harness
in 5 Easy Steps
Custom Wiring Harness and Order Review Process
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
Custom Wiring Harness Case Studies
Case Study
This project involved designing and manufacturing a high-flexibility, lightweight wire harness for a six-axis collaborative robot (cobot) arm used in precision assembly tasks. The harness needed to withstand continuous motion cycles, resist abrasion, and maintain signal integrity for servo feedback and sensor data.
Product Specifications:
- Conductor Material: 18 AWG tinned copper for power lines
- Insulation: Fluoropolymer (PTFE) inner jacket
- Shielding: Spiral-wrapped tinned copper over control/sensor pairs with overall PVC jacket to ensure EMI protection in high‐noise environments
- Flex Life: > 10 million cycles at 180° bend radius (≥ 10 mm)
- Temperature Range: −40 °C to +105 °C
- Number of Circuits: 22 (6× power phases, 8× encoder/feedback pairs, 8× digital I/O)
Case Study
In this project, a modular wire harness was developed for a high-throughput automated parcel-sorting conveyor system. The harness architecture allowed quick replacement of individual conveyor segments and integrated power, data, and pneumatic tubing lines into a single, easy-to-install assembly that maintains IP67 protection in dusty, washdown-prone warehouse environments.
Product Specifications:
- Conductor Material: 16 AWG stranded copper for power buses
- Composite Bundle: Integrated 6 mm pneumatic TPU tubing for ejection actuators (PN ≤ 10 bar) plus 8 mm braided grounding conductor
- Shielding: Overall aluminum-mylar foil with tinned copper braid (≥ 85% coverage) for signal integrity over long runs
- Modularity: Pre-terminated field-replaceable segments in 1 m lengths, snap-lock IP67-rated connectors for power (L-N-PE) and M12-D-coded Ethernet
- Temperature Rating: −20 °C to +80 °C
Case Study
In this case study, there was the development of a compact, high-voltage wire harness for an electric vehicle (EV) manufacturer’s next-generation powertrain module.
Product Specifications:
- Conductor Material: 4 AWG Class D tinned copper for main battery outputs
- Insulation & Jacket: Cross-linked thermoset elastomer (XLETFE) for high-voltage lines
- Voltage Rating: 1,000 V DC (UL 2580) for high-voltage circuits
- Shielding: Individual tinned-copper spiral shielding on all communication pairs
- Connectors: IP69K-rated TE Connectivity HVP3 for battery interface
- Temperature Range: −40 °C to +125 °C (continuous) & 150 °C short-term survivability
- Vibration & Impact: Compliant with ISO 16750-3 vibration profiles
Client Feedback On Custom Wiring Harnesses
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 design, manufacturing, and testing of custom wiring harnesses 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 tested our company’s custom wiring harness after assembly, they found a potential connection issue which many engineers had never identified in the past years. But their attention to detail caught it immediately. The wiring harness 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 custom automotive wiring harness with 10 connection points, and I can’t wait to receive my harness. So I used expedited service and received my wiring harness in three days. I tested and installed the harness, Quality is really good, cable routing, connector crimping also great.
Warren Cliton
Custom Wiring Harness Manufacturer FAQs
What is your minimum order quantity?
We have no minimum order quantity.
What payment methods do you accept?
We accept multiple secure payment options, including PayPal, bank transfer (T/T), Western Union, and MoneyGram.
Can you mix wire gauges in one harness?
Yes, we can build harnesses with mixed wire gauges, insulation types, and even hybrid structures combining wires and tubing within the same flat or bundled cable. Each combination is engineered to meet voltage, current, and environmental specs.
Can I request a custom label on each harness?
Yes, we offer custom labeling options including barcodes, alphanumeric IDs, serialized tags, and customer-specific part numbers. Labels can be applied directly to the wire, jacket, or packaging.
Do you offer waterproofing or overmolding?
Yes, we provide IP67/IP68-rated waterproofing using sealed connectors, grommets, and gel seals. Custom overmolding with PVC, TPE, or polyurethane is also available for junction protection, strain relief, and environmental shielding.
Get $100 Off Your First Custom Wiring Harness Order
Work with a globally trusted custom wiring harness manufacturer for your next project. Whether you need 10 harnesses or 10,000+, WellPCB delivers certified, fully tested wiring harness assemblies manufactured to your specifications.
