Box-Build Wiring
Custom cable harnesses and wire assemblies built to IPC/WHMA-A-620, UL, silicone, PTFE wire. Crimped, soldered, tested. Integrated with your PCB assembly for turnkey delivery.
Wire & Cable Options
UL 1007/1015/1061 series. 300V or 600V rating, 80C to 105C temperature range. AWG 28 to AWG 10 available. Solid and stranded conductors. Ideal for internal appliance wiring, control panels, and consumer electronics. Full UL traceability with lot-level certification.
Silicone rubber insulated (UL 3122/3135): 150C to 200C continuous. PTFE/Teflon (UL 1330/1332): 200C rating with exceptional chemical resistance. Used in automotive engine compartments, industrial ovens, medical sterilization equipment, and aerospace harnesses.
Flat ribbon cable (0.635mm/1.27mm pitch) with IDC connectors. Miniature coaxial (RG178/RG316) for RF interconnects. Braided-shield multi-conductor cable with drain wire termination. Twinax and differential-pair harnesses for high-speed data.
We terminate the full range of connector systems used in modern electronics: JST (PH/XH/PA/EH/VH series), Molex (Mini-Fit, Micro-Fit, PicoBlade, CLIK-Mate), TE/AMP (MATE-N-LOK, FASTON, Micro-MaTch), Hirose (DF13/DF52), JAE, and Samtec. Automated crimping machines with force monitoring ensure consistent gas-tight crimps on every terminal, no intermittent connections in the field.
For board-to-wire applications, we solder wires directly to PCB pads when connectors are impractical, strain-relieved with adhesive-lined heat-shrink and secured with cable ties to dedicated anchor points on the board or enclosure.
| Test | Method | Standard | Pass Criteria |
|---|---|---|---|
| Continuity | Automated flying-probe harness tester, 128-point | IPC/WHMA-A-620 | Resistance < 1Ω per circuit, no opens |
| HI-POT (Dielectric) | AC/DC hipot tester, programmable ramp | IEC 60243, UL 758 | No breakdown at 2× rated voltage + 1000V |
| Insulation Resistance | Megohmmeter, 500VDC test voltage | IPC/WHMA-A-620 | > 100 MΩ between all conductors |
| Crimp Pull-Force | Motorized tensile tester with digital gauge | UL 486A / SAE AS7928 | Per UL spec by wire gauge (e.g., > 8 lb for AWG 22) |
| Crimp Cross-Section | Microscope inspection at 20–30×, cut and polish | IPC/WHMA-A-620 Class 2 | No voids > 5%, strands not deformed, full barrel fill |
| Visual Inspection | 100% under magnification (3–5× ring light) | IPC/WHMA-A-620 | No damaged insulation, correct wire color/gauge, label legible |
Your harnesses are built alongside your PCB assemblies, not at a separate supplier. This means the harness team has access to the actual PCBs, connectors, and enclosures during fabrication. Pre-fit checks on real hardware eliminate the back-and-forth of working with drawings alone.
Every harness is bundled, labeled with your part number and revision, and kitted with the corresponding PCBs and enclosures for final box-build assembly. Cable management inside the enclosure, routing clips, spiral wrap, braided sleeving, cable ties with mounting bases, is performed at the system integration station as part of the full build process.
AWG 32 to AWG 4/0. Single-conductor, multi-conductor, shielded, twisted-pair, flat ribbon. Metric equivalents stocked for European customers.
Open-barrel crimp, closed-barrel crimp, insulation-displacement (IDC), solder cup, PCB solder (through-hole and SMD), screw terminal, spring clamp.
Adhesive-lined dual-wall heat-shrink (3:1 and 4:1 ratio), molded strain relief boots, spiral wrap, braided expandable sleeving (PET/nomex), grommet edging.
Heat-shrink tube printing (Brady/M21 series), self-laminating wrap-around labels, cable marker ties. Text, barcode, QR code. Resistant to IPA, MEK cleaning.
IPC/WHMA-A-620 Class 2 and Class 3. UL ZPFW2/ZPFW8 recognized. ISO 9001. IATF 16949 for automotive harnesses. UL traceability per spool.
Single prototype harness to 10,000+ units/month. Semi-automated cut/strip/crimp machines for volume. Manual bench for complex or low-volume assemblies.
Send your wiring diagram or harness drawing. We quote within 24 hours: including connector sourcing, fabrication, and 100% electrical testing.
Upload Gerber + BOM, 24h quote with free DFM review.