Built to order · 18 assemblies
Custom Wire Harness Manufacturing
Built-to-print harnesses for rail, aerospace, medical, EV and semiconductor equipment — including EN 45545-2 rail builds, 800 V EV battery harnesses, MIL-DTL-38999 and Micro-D avionics looms, and cleanroom robot cabling. We work from your drawing, BOM or sample.
- Rail
- EN 45545-2 · rolling stock
- Aerospace
- MIL-DTL-38999 · Micro-D · Nano-D
- Medical
- Surgical robot · sealed joints
- EV / storage
- 800 V · BESS 1000–1500 V
- Robotics
- EFEM · vacuum · wafer handling
- Validation
- Continuity · hipot · HVIL
- Jacket
- Silicone · PUR · PTFE
- Volume
- Prototype to production
Memory Wire Composite Harness, Enameled Copper on Steel Core
Specification table
A harness is not picked from a catalog; it is built to your drawing, BOM or sample. What matters is how the branch points are made, how each joint is protected and what evidence ships with the assembly. Workmanship runs to IPC/WHMA-A-620 Class 3 criteria, and every unit is tested before it leaves.
| Parameter | Standard build | Available on request |
|---|---|---|
| Build input | Drawing, BOM or physical sample | Reverse-engineered samples with a build report |
| Connector types | MIL-DTL-38999, Micro-D and Nano-D, D-Sub, M12 | D38999 series I/II/III, custom shells |
| Conductor range | 32 to 10 AWG single or multi-branch | Busbar and screened HV branches |
| Protection | Braided sleeving and heat shrink transitions | Conduit, potted breakouts, molded strain relief |
| Breakout geometry | Single point to multi-branch with marked lengths | Clocked plugs so each branch falls into place |
| Workmanship | IPC/WHMA-A-620 Class 3 criteria | Nadcap-style or customer documentation packages on request |
| Testing | 100 percent continuity and hipot | Insulation resistance, HVIL checks, functional test racks |
| Volume | Prototype through repeat production | Pilot builds before tooling commitment |
| Materials | RoHS and REACH compliant as standard | UL style recognition, rail fire/smoke/toxicity grades |
Workmanship is built to IPC/WHMA-A-620 Class 3 criteria, published by IPC and WHMA; rail builds follow the fire, smoke and toxicity grades referenced in EN 45545-2.
Typical applications
- Rail rolling stock EN 45545-2 graded materials and documented fire performance.
- Aerospace and defense MIL-DTL-38999 based looms with tight potting and marking requirements.
- Medical devices Surgical robotics and cleanroom-rated assemblies with full traceability.
- Energy storage High-voltage battery and BESS harnesses with HVIL monitoring circuits.
- Semiconductor equipment EFEM, vacuum and wafer-handling cabling.
Related reading
- Wire Harness Drawing Checklist for OEM BuyersCallouts, tolerances and test notes that separate a quotable drawing from a round of emails.
- MIL-DTL-38999 vs M12What the tenfold price difference buys in shell strength, sealing and qualification paperwork.
- How to Prepare a Custom Cable Assembly RFQThe fields a supplier needs before quoting: interface, length, environment, quantity and drawing.
Questions buyers ask
What do I need to send to get a quote?
A drawing or sample plus the connector part numbers, wire specifications and branch lengths. If you do not have a harness drawing yet, our drawing checklist for OEM buyers lists exactly what the build team asks for.
Is there a minimum order quantity?
Prototypes and samples start from 1 to 50 pcs. Production pricing starts at 500 pcs per part number once the assembly is proven and a tooling or fixture investment makes sense, and we say so in writing before recommending it.
Is MIL-DTL-38999 worth the cost over M12?
Usually not for a factory floor sensor. It earns its price in vibration, altitude and environmental sealing cases. We priced the difference in MIL-DTL-38999 versus M12.
Have one built to your drawing
Send the connector part numbers, lengths and environment. We review manufacturability in writing before any tooling spend, and we tell you up front what we cannot do.