Custom Wire Harness & Cable Assembly Manufacturer
From prototype to mass production, we deliver precision-engineered wire harness and cable assembly solutions. 48-hour rapid prototyping with no minimum order quantity.
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We back our promises with contractual SLAs and financial penalties. Not just marketing claims—verifiable commitments.
Dual Factory Redundancy
China (Shenzhen) + Philippines (Laguna) dual-factory strategy. 85% product overlap capability. If one facility faces disruption, production transfers within 72 hours.
98.7% On-Time Delivery
Based on 2024 YTD data (Jan-Nov). DDP delivery to EU/US available. Sea freight: 4-5 weeks. Air freight: 5-7 days. We absorb delay penalties per contract.
4-Hour Technical Response
Native-speaking engineers (EN/DE/FR/ES/ZH). Technical inquiries: 4 business hours. Quotations: 48 hours standard, 5 days for custom engineering.
<50 PPM Defect Rate
2024 Q3 actual: 47 PPM (improved from 62 PPM in Q2). IATF 16949 by TÜV SÜD. 100% electrical testing. IPC/WHMA-A-620 Class 3 workmanship.
Verifiable Certifications
Verify AllTotal Landed Cost Comparison vs. EU Tier-2 Suppliers
- Avg. 42% TLC Reduction - DDP Europe, based on 50+ projects in 2024. Includes freight, duty, and quality inspection costs.
- One-Stop EMS - DFM review, prototyping, testing, production, box-build assembly. Reduce your supplier management overhead.
- 48h Prototypes - vs. 2-3 weeks typical EU lead time. Accelerate your development cycle by 4-6 weeks.
- US GSP Eligible - Philippines production qualifies for duty-free entry. Save 3.5-6% on US imports.
Standard Terms
Wire Harness & Cable Assembly Solutions
From concept to production, we provide end-to-end wire harness and cable assembly manufacturing services.
Custom Wire Harness
Complete wire harness solutions from design to production, including waterproof, high-voltage, and EMI shielded harnesses.
- Automotive Grade
- Medical Device
- Industrial Control
- Aerospace
Cable Assembly
Precision cable assemblies with major connector brands including Molex, JST, TE Connectivity, and more.
- Overmolded Cables
- Multi-Conductor
- Coaxial Assembly
- Custom Connectors
Rapid Prototyping
48-hour quick-turn prototyping services from our China facility with design validation and first article inspection.
- 48h Turnaround
- Low Volume OK
- Design Review
- Fast Iteration
Why Choose OurPCB for Wire Harness Manufacturing?
We combine engineering expertise with flexible manufacturing to deliver wire harness solutions that meet your exact requirements.
No Minimum Order
From 1 piece prototype to mass production, we handle orders of any size.
48-Hour Prototyping
Rapid turnaround for urgent projects from our China facility.
Dual Factory Strategy
China for speed, Philippines for US tariff-free mass production.
Full Certifications
IATF 16949, ISO 13485, ISO 9001, UL listed for quality assurance.
See Our Wire Harness Manufacturing in Action
Take a virtual tour of our state-of-the-art wire harness manufacturing facility. Watch our skilled technicians and automated equipment produce high-quality cable assemblies with precision and efficiency.
- Automated wire cutting and stripping
- Precision terminal crimping
- 100% electrical testing
- Quality control processes
Real Projects. Audited Results.
Reference contacts available under NDA. All metrics from customer scorecards and internal QMS data.
EV Battery Harness: 60% Cost Reduction
Facing 16-week lead times and €45/unit from local suppliers. Production deadlines at risk. 3 existing suppliers causing quality inconsistency.
FDA-Compliant Cable Assembly
Previous supplier failed FDA audit with 5 findings. Product launch delayed 4 months. Needed ISO 13485 + full lot traceability.
High-Flex Robot Arm Cables
Existing cables failing at 5-7M cycles (spec: 10M). Field failures costing €15K+ per warranty claim. EU suppliers couldn't meet flex spec.
Transparency Note
Client names anonymized per NDA. Reference contacts available for qualified buyers during supplier qualification. All metrics verified via customer scorecards or our QMS. We share both successes and challenges encountered— because we solve problems, we don't hide them.
How We Compare (Honestly)
We're not the cheapest. We're not the fastest. But we might be the best value for your specific needs. Here's a transparent comparison.
| Criteria | Us China + Philippines | Local Supplier US / EU based | Generic Offshore Low-cost Asia |
|---|---|---|---|
| Certifications | |||
| IATF 16949 (Automotive)Only 15% of wire harness suppliers globally hold IATF 16949 | |||
| ISO 13485 (Medical) | |||
| UL/CSA Recognition | |||
| Pricing | |||
| Landed Cost (Index)Indexed to our pricing. Lower is better. | 100 | 180-250 | 85-95 |
| Transparent Cost Breakdown | |||
| Volume Tier Pricing | |||
| Lead Time | |||
| Sample Lead Time | 5-7 days | 3-5 days | 10-15 days |
| Production Lead Time | 2-4 weeks | 2-3 weeks | 4-8 weeks |
| Rush Order Capability | |||
| Quality | |||
| Avg. PPM RateParts per million defects. Lower is better. | <80 PPM | 100-200 PPM | 300-500 PPM |
| 100% Electrical Testing | |||
| Full Lot Traceability | |||
| Capabilities | |||
| In-House Wire Cutting | |||
| Overmolding | |||
| Clean Room (Medical) | |||
| Support | |||
| English Technical Support | |||
| DFM Feedback | |||
| Dedicated PM | |||
| Risk Mitigation | |||
| Dual-Site ProductionChina + Philippines dual-factory capability | |||
| Tariff-Free OptionsPhilippines production for US/EU tariff avoidance | N/A | ||
| Safety Stock Programs | |||
Choose Local If...
- • You need samples in 48 hours
- • Volume is under 1,000 units/year
- • Budget is not a primary concern
- • Domestic sourcing is mandated
Choose Us If...
- • You need certified quality (IATF/ISO 13485)
- • Volume is 5,000+ units/year
- • You want cost savings with quality
- • Supply chain resilience matters
Choose Generic Offshore If...
- • Price is the only factor
- • Quality tolerance is high (300+ PPM OK)
- • No certification requirements
- • You can manage QC yourself
Disclaimer: Comparison based on industry averages and our experience. Individual suppliers vary. "Local Supplier" refers to typical US/EU-based wire harness manufacturers. "Generic Offshore" refers to non-certified Asian manufacturers. Request specific data for accurate comparison.
Want a side-by-side comparison with your current supplier?
Request Custom ComparisonEngineering for Precision
Our wire harness manufacturing processes are designed to deliver reliable, high-quality cable assemblies for the most demanding applications.
Custom Wire Harness
- Automotive Grade Wiring
- Medical Device Cables
- Industrial Control Harnesses
- Aerospace Wiring Systems
Cable Assembly
- Overmolded Assemblies
- Multi-Conductor Cables
- Shielded & Jacketed
- Custom Connectors
Rapid Prototyping
- 48-Hour Quick Turn
- Low Volume Production
- Design Validation
- First Article Inspection
Quality Assurance
- 100% Electrical Testing
- Visual Inspection
- Pull Force Testing
- Continuity Verification
Industries We Serve
Automotive
High-reliability wire harnesses for ECU, sensors, infotainment, and EV battery systems.
Medical Devices
Precision cable assemblies for diagnostic equipment, patient monitors, and surgical systems.
Industrial Control
Rugged wiring solutions for automation, robotics, and heavy machinery applications.
Robotics
Flexible, high-flex cable harnesses designed for robotic arms and motion systems.
What is Wire Harness Manufacturing?
Wire harness manufacturing is the process of assembling multiple electrical wires, cables, and connectors into a single organized bundle. These harnesses transmit signals and power throughout vehicles, machines, and electronic devices, forming the essential nervous system of modern equipment.
At OurPCB, we specialize in custom cable assembly and wire harness production for automotive, medical, industrial, and aerospace applications. Our facilities are equipped with automated cutting, stripping, and crimping machines to ensure precision and consistency.
Wire Harness vs. Cable Assembly
Technical Comparison| Feature | Wire Harness | Cable Assembly |
|---|---|---|
| Structure | Multiple wires bound with tape, ties, or conduit | Wires enclosed in protective outer jacket/sheath |
| Primary Use | Internal device/vehicle wiring, space-constrained areas | External connections, harsh environments |
| Protection Level | Basic organization, some abrasion resistance | High protection from moisture, chemicals, EMI |
| Flexibility | More flexible, easier routing | Less flexible, more durable |
Need design assistance?
Our engineering team can help with connector selection, wire gauge optimization, and routing recommendations for your wire harness project.
Frequently Asked Questions
Common questions about our wire harness manufacturing process.
Ready to Start Your Wire Harness Project?
Submit your design specifications for a free quote. Our engineering team is ready to help with your custom cable assembly requirements.
Need help with specifications? Contact our engineering team