High Voltage Cable Assembly
Custom high voltage cable assemblies for EV platforms, energy storage, rail, and industrial electrification programs that need controlled shielding, durable terminations, and 100% electrical verification.
Voltage Platforms We Support
High voltage cable assembly work changes significantly with platform voltage, current density, and service environment, so we define the build around the real use case.
High Voltage Assembly Priorities
The challenge is rarely just voltage rating. Most sourcing programs are balancing EMC, packaging, safety, field service, and recurring manufacturability at the same time.
Shielded HV Construction
Braided, foil, or hybrid shielding strategies control EMI around inverters, motors, chargers, and other high-noise power electronics.
High-Current Termination Control
Large-gauge conductor preparation, crimp validation, and lug or connector retention checks are built into the process plan for repeatable conductivity.
Safety-Driven Identification
Orange jackets, clear labeling, and controlled routing documentation help installers and service teams identify high-energy circuits quickly.
Environmental Protection Options
Heat shrink, boots, seals, conduit, and overmolded transitions are selected around vibration, abrasion, fluids, and thermal exposure.
Prototype To Production Support
We support bench prototypes, pilot builds, and recurring production with fixture-backed testing and change control on critical dimensions.
Multi-Segment System Builds
Programs often include branch assemblies, jumpers, busbar-adjacent leads, and connectorized subassemblies rather than a single simple cable.
Built Around Power, Packaging, And Safety
Program Fit
Electric Vehicles
Battery pack, inverter, DC-DC converter, and e-axle interconnects for 400V and 800V vehicle platforms.
Energy Storage Systems
Battery rack jumpers, inverter leads, and power distribution assemblies for stationary storage and backup systems.
Industrial Electrification
Power conversion, motor drives, and machine-level HV connections where shielding and serviceability both matter.
Rail And Transit
Ruggedized cable sets for auxiliary power, onboard conversion, and rolling stock subsystems exposed to vibration.
Controlled Steps For High-Energy Interconnects
High voltage cable assemblies are process-sensitive because conductor handling, connector geometry, and shielding termination all affect both performance and safety. We use work instructions and test fixtures built around the actual program instead of forcing every job into a generic cable workflow.
- Review the operating voltage, current profile, connector family, bend space, and thermal environment before selecting cable construction.
- Define conductor cross-section, shielding strategy, insulation system, and strain-relief approach around the real installation geometry.
- Prepare large-gauge conductors with controlled strip dimensions and validated crimp or lug attachment methods.
- Assemble branch points, breakouts, and connector transitions using fixtures that hold polarity and pinout accuracy through the full build.
- Run 100% electrical verification including continuity, polarity, insulation checks, and hi-pot where the program requires it.
- Package assemblies with identification, protection, and documentation matched to service, installation, and audit needs.
Common Related Builds
Many high voltage cable assembly programs are part of a larger electrification package, so customers often source adjacent assemblies from the same manufacturing partner to simplify validation and logistics.
Custom High Voltage Cable Assembly For EV, Energy Storage, And Industrial Power
As a specialized high voltage cable assembly manufacturer, OurPCB builds power interconnects for electrified systems where current load, shielding, routing space, and safety controls all need to be managed together. These assemblies are commonly used between batteries, inverters, chargers, converters, and distribution units in programs that cannot accept inconsistent termination quality or vague test records.
The compliance framework around these products often draws from recognized safety and electrical standards bodies such as the International Electrotechnical Commission and UL. For automotive-adjacent programs, identification practices and circuit segregation are also shaped by vehicle service expectations and OEM-specific design rules. That is why our process starts with the real system architecture rather than only a conductor size and a connector part number.
Compared with a broader high-voltage wire harness, a cable assembly usually focuses on a smaller number of critical power paths. That makes shielding, lug or terminal attachment quality, and transition protection even more visible to the end customer. We frequently build these products alongside battery cable assemblies, EV charging cable assemblies, and connectorized power assemblies that integrate into larger electrified platforms.
Electrified equipment is also pushing voltage and current upward as efficiency targets get tighter. The system-level architecture discussed in the electric vehicle battery overview helps explain why cable routing, insulation selection, and thermal planning matter so much in 400V and 800V platforms. We build around those realities with fixture-backed production, clear polarity control, and 100% electrical verification before shipment.
If your program includes sealed power connectors, large-gauge conductors, branch transitions, or documentation requirements for pilot and production builds, we can align the assembly plan to your validation path. Our testing team supports cable verification, and our molding capabilities can reinforce exposed transition points where strain relief or environmental sealing is required. Contact us to review drawings, target quantities, and project timing.
From the Case Bank
A German industrial electrical systems integrator required cable harnesses for a high-volume annual program but faced sourcing constraints on specified connectors.
The originally specified STOCKO connectors faced procurement limitations, and the required PTC components (EPCOS B59100A1080-A40) had a long 12-14 week lead time, threatening the overall project timeline for a 200kpcs/year program.
Proposed Lumberg connectors as a qualified alternative to STOCKO. Provided detailed specification comparisons and emphasized Lumberg's shorter MOQ and better delivery times to offset the PTC lead time bottleneck, while remaining transparent about the slightly higher price point of the alternative.
The customer accepted the alternative for evaluation, agreeing to sample the Lumberg-based assemblies, which kept the high-volume annual program viable despite initial component sourcing bottlenecks.
- 100kpcs/year per product (200kpcs total annual volume)
- PTC model: EPCOS B59100A1080-A40
- PTC lead time: 12-14 weeks
- Connectors evaluated: STOCKO vs. Lumberg
High Voltage Cable FAQ
A high voltage cable assembly is usually a defined power cable or cable set with specific conductors, shielding, and terminations linking major subsystems such as batteries, inverters, or chargers. A high voltage wire harness can include multiple branch circuits, clips, retainers, and integrated routing hardware across a wider vehicle or machine architecture. We support both, but this page focuses on the cable assembly side of the work.
Yes. We support both 400V and 800V platform requirements for battery, inverter, charging, and auxiliary power connections. The exact cable construction, shielding, and connector system are selected against current load, thermal conditions, and installation space rather than using a one-size-fits-all template.
Typical tests include continuity, polarity, insulation resistance, and hi-pot verification, plus connector retention or pull checks when the program calls for them. We can also align fixture design and record format to your internal validation or customer documentation requirements.
Yes. High voltage cable assemblies often need environmental sealing and durable strain relief at connector transitions. We can build with sealed connector systems, boots, heat shrink, conduit, and overmolded sections depending on the exposure profile and service strategy.
The most common programs come from EV platforms, charging systems, stationary energy storage, rail equipment, industrial power conversion, and other electrified systems where high current and higher operating voltage require controlled assembly methods and documented testing.
Need High Voltage Cable Assemblies?
Send your drawings, connector targets, operating voltage, and build quantities for a fast review from our cable assembly team.