Industries

Cable Assemblies for Automotive & EV

An automotive harness is asked to survive vibration it cannot damp, temperature swings it cannot avoid, and fluids it cannot repel — for years, without access. The assembly is the easy part; proving it will last is the work.

What this application demands

These are the constraints that change the design. Everything else is a normal cable.

Vibration
Continuous low-amplitude vibration loosens terminations and work-hardens stranded conductors at the crimp. Strain relief and retention features carry the load, not the solder joint.
Temperature cycling
Under-hood and exterior locations swing far further than cabin electronics. Jacket and overmold materials are selected for the range, not the average.
Fluid exposure
Oil, fuel, coolant and road salt. Material selection is driven by what the harness is routed past.
Connector retention and locking
Positive latching plus an overmold that supports the connector body, so vibration loads do not reach the crimp.
Abrasion and routing
Loom, sleeving and clip points. Most harness failures are chafe at a routing point, not electrical.

Typical builds

  • Dashcam and rear-view camera harnesses
  • OBD2 and J1939 adapter and extension cables
  • Battery-management and sense-lead assemblies
  • Sensor and actuator harnesses with overmolded grommets
  • Overmolded seals and panel feedthroughs

Documentation: what we provide

First-article inspection
Yes — dimensional and electrical FAI reports, produced to your format.
PPAP
We do not claim PPAP submission. If your programme requires it, we will tell you at quotation so you can qualify us honestly.
Crimp verification
Pull-force testing per conductor size against IPC/WHMA-A-620 workmanship criteria, with results retained per batch.
Electrical testing
Continuity and pinout 100%. Insulation resistance, hipot and contact resistance per the agreed test scope.

IPC/WHMA-A-620 Class 3 is the workmanship criteria we build and inspect to. We state it as the standard we work against; we do not claim a certificate we do not hold.

What we ask before quoting

Answer these with the drawing and the quotation will be meaningful on the first pass.

  1. Mounting location and temperature range
  2. Vibration profile, if you have one
  3. Fluids the harness is routed past
  4. Mating connector part numbers
  5. Documentation required: FAI, dimensional, test data
  6. Annual volume and expected order pattern

Send the specification and the mating connectors

We will confirm what the cable has to survive, flag anything that will cost you money without adding function, and quote against your drawing.

REQUEST A QUOTE