Power Wire Harness
Professional power wire harness manufacturing for high current applications. Battery cables, power distribution, and motor feeds with heavy gauge wire and industrial-grade connectors.
Power Harness Applications
Power distribution for demanding applications.
Battery Connections
Main battery cables, jump start posts, and battery management
Power Distribution
Fuse boxes, power panels, and distribution modules
Motor Feeds
Starter motors, EV drive motors, and industrial motors
DC Power Systems
12V, 24V, 48V and high voltage DC power distribution
Ground Circuits
Chassis grounds, battery returns, and grounding straps
High Current Feeders
Alternator outputs, inverter connections, and charging circuits
Power Harness Features
Essential capabilities for power applications.
Heavy Gauge Capability
Manufacturing from 16 AWG down to 4/0 AWG for high current applications
Crimped & Soldered Terminals
Precision crimping and soldering for reliable power connections
Voltage Drop Optimization
Proper wire sizing to minimize voltage drop and power loss
Robust Connectors
Industrial-grade connectors rated for high current and vibration
Power Harness Specifications
Power Engineering
Our engineering team ensures proper wire sizing, connector selection, and protection for your power requirements. We calculate voltage drop and verify thermal performance for reliable power delivery.
- Voltage drop calculations
- Current capacity verification
- Heavy gauge crimping expertise
- UL/CSA listed materials
Professional Power Wire Harness Manufacturing
OurPCB manufactures power wire harnesses for high current applications across automotive, industrial, and renewable energy sectors. From battery cables to motor feeds, we build power harnesses that deliver reliable current flow with minimal voltage drop.
Our heavy duty manufacturing capabilities include crimping wire from 16 AWG to 4/0 AWG using precision hydraulic tooling. We use UL listed wire and connectors for safety-critical power applications.
For high voltage EV systems, we manufacture orange-jacketed power harnesses with appropriate shielding and safety features. Our EV and new energy experience includes battery pack connections, inverter feeds, and charging system harnesses.
Use our voltage drop calculator to determine proper wire sizing, or contact our engineers to discuss your power distribution requirements.
Power Harness FAQ
We manufacture power harnesses from 16 AWG for lighter applications up to 4/0 AWG (0000) for high current battery and motor circuits. Our crimping and termination equipment handles the full range of heavy gauge automotive and industrial wire.
We calculate wire gauge requirements based on your current specifications, ambient temperature, and allowable voltage drop. Our engineers verify that wire sizing, connector ratings, and protection meet your power requirements with appropriate safety margins.
We use various power connectors including ring terminals, battery lugs, Anderson PowerPole, Deutsch high-current, and OEM-specific battery posts. Connector selection is based on current rating, connection method, and environmental requirements.
Yes, we manufacture high voltage power harnesses for EV applications including battery pack connections, motor feeds, and charging circuits. These harnesses use orange-jacketed HV-rated wire, shielding, and appropriate safety features per automotive HV standards.
Need Power Wire Harnesses?
From battery cables to high current motor feeds, we manufacture power harnesses with proper sizing and industrial-grade components.