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Automotive Wire Harness Manufacturers

Last updated: January 2026

This directory lists 88 automotive wire harness manufacturers across the United States, from prototype and low-volume specialists serving niche markets to high-volume Tier 1 and Tier 2 suppliers supporting major OEM programs.

Buyers engage these manufacturers to solve a range of critical vehicle integration challenges, from developing robust engine harnesses capable of withstanding extreme thermal cycling and fluid exposure, to designing compact, signal-rich harnesses for sophisticated infotainment and ADAS modules requiring precise EMI shielding. They seek partners who can deliver solutions that ensure reliable power distribution, seamless data transmission, and protection against vibration and moisture ingress, often necessitating advanced capabilities like potting, overmolding, or specialized splicing techniques.

Suppliers in this space vary significantly, encompassing dedicated custom harness builders offering extensive design for manufacturability (DFM) services, contract manufacturers focused solely on build-to-print, and those specializing in particular applications like battery management systems (BMS) or heavy-duty vehicle wiring. Their distinctions often lie in their engineering depth, in-house testing facilities (e.g., vibration, thermal shock chambers), and their readiness to execute comprehensive Production Part Approval Process (PPAP) documentation and adhere to Advanced Product Quality Planning (APQP) methodologies.

88 companies·64 emails·76 phones

Company Directory

88 companies nationwide

Valencia, CA

Based in Valencia, CA, A and M Electronics, Inc. is a contract manufacturer specializing in custom wire harnesses, electronic cables, circuit board assembly, and box builds. They serve the military, medical, and commercial industries, building high-quality components to customer specifications and industry standards.

Manteca, CA

Based in Manteca, CA, ALF Industries specializes in custom wire harness manufacturing and cable assembly services. They provide essential electrical connectivity solutions for various industrial applications, serving diverse sectors including automotive clients with robust and reliable components.

Bellmawr, NJ

Based in Bellmawr, NJ, American Autowire manufactures hand-built automotive wiring harnesses and kits. Their Southern New Jersey facility produces over 10,000 wiring products for diverse automotive projects. Specializing in GM OEM restoration, restomod, and classic vehicle updates, they offer comprehensive electrical solutions.

Justin, TX

Based in Justin, TX, American Made Harness specializes in manufacturing custom cable assemblies, wire harnesses, RF cables, and electronic component kitting. They leverage the latest technology to provide cost-effective, quality products with great customer service and on-time delivery for various industry-leading projects.

Hampshire, IL

Based in Hampshire, IL, American Precision Assemblers, Inc. is a national manufacturer of custom wire harnesses, cable assemblies, and electronic sub-assemblies. They also provide electronic box build and electro-mechanical pneumatic assembly services. The company holds ISO 9001:2015 and AS9100D certifications.

Fremont, CA

Based in Fremont, CA, BAYCABLE manufactures custom electro-mechanical, molded, and specialty cable assemblies, alongside coil cords. Certified ISO 9001:2015 and ISO 13485:2016, they provide in-house engineering and production from prototype to medium volume, serving OEMs and ODMs.

Brenham, TX

Based in Brenham, TX, BENCOR LLC specializes in custom cable assembly and wire harness manufacturing services. Their in-house processing team optimizes and perfects solutions for various applications, serving clients across Texas and throughout the United States.

San Jose, CA

Bentek Corporation, based in San Jose, CA, is a US manufacturer of custom wire harness and cable assemblies. The company operates facilities in California and Nevada, offering prototyping, NPI, and engineering support. Bentek serves diverse sectors, prominently including the automotive, medical, industrial, and renewable energy industries.

Botkins, OH

Based in Botkins, OH, Buckeye Electrical is a family-owned manufacturer established in 1995. The company specializes in producing quality wire harnesses, cable assemblies, and power cables, alongside custom assemblies and box builds. They offer capabilities like cutting, crimping, and ultrasonic welding. Buckeye Electrical serves diverse sectors including industrial, recreational, military, and medical industries.

Fremont, CA

Based in Fremont, CA, Cable Connection specializes in the manufacturing of custom cable assemblies and wire harnesses. The company provides tailored wiring solutions specifically designed for a variety of automotive applications, meeting industry standards for performance and reliability.

Irvine, CA

Carr Manufacturing Company provides custom wire harness assembly and cable harness fabrication services. They offer box build solutions and manufacture power supplies, adhering to MIL-AERO standards. This woman-owned business serves diverse industries from its facility in Irvine, CA.

El Paso, TX

Cesar-Scott Inc manufactures wire harnesses and cable assemblies. Based in El Paso, TX, the company holds IPC and WHMA certifications, focusing on producing high-quality electrical interconnect solutions. They provide custom manufacturing services for various industries requiring reliable wiring components.

PKC Cable, Harness, and Electro-Mechanical Assembly provides specialized assembly services with over 45 years of experience. The company manufactures cable, harness, and electro-mechanical assemblies for diverse sectors including the Automotive, Military, Medical, Aerospace, and Satellite markets.

Jersey Village, TX

Based in Jersey Village, TX, Complete Custom Cables LLC designs and manufactures a vast array of wire harnesses, cable assemblies, and overmolded assemblies. The company specializes in providing custom electromechanical manufacturing solutions for various industries. They also produce custom racks, control panels, and sheet metal components.

Barberton, OH

Based in Barberton, OH, Custom Auto Wiring (CAW) manufactures and assembles wire harnesses. CAW specializes in short to medium production runs (10-10,000 units) for automotive aftermarket, restoration, and industrial OEM clients. They offer custom connectors, injection molding, and wire/terminal over molding, with JIT programs and 2-4 week lead times.

Dallas, TX

Based in Dallas, TX, Cypress Industries is a global contract manufacturer specializing in custom automotive wire harnesses. The company also produces PCBA's, custom cables, control panels, plastic injection molding, and machined parts. They operate manufacturing facilities in Austin, TX, among other international locations.

San Jose, CA

Based in San Jose, CA, DC Electronics manufactures custom cable wire harnesses and assemblies. They specialize in high-density, overmolded, and discrete assemblies. Serving aerospace, medical, industrial, and agricultural equipment markets, they leverage extensive capabilities from their US and Mexico facilities.

Vista, CA

Based in Vista, CA, DDH Enterprise, Inc. specializes in contract manufacturing for EV/automotive cable and wire harness production. They provide customized high voltage EV cable solutions and low voltage wire harnesses, built to OEM specifications. The company also offers specialty harness assemblies, medical cables, power cables, and box build solutions.

Spring, TX

Based in Spring, TX, Defender Supply specializes in custom wire harness manufacturing for automotive fleet applications. The company engineers bespoke electrical connectivity solutions tailored to client specifications. They focus on delivering high-quality, reliable components for commercial and industrial vehicles, ensuring consistent performance.

Wellington, KS

Elite Harness, located in Wellington, KS, manufactures electrical wire harnesses and custom cables. The company builds to exact customer specifications, utilizing advanced equipment for precision and efficiency. It serves industries such as transportation, vehicle upfitters, heavy industry, and agricultural equipment, delivering reliable, quality products on time.

Based in Bedford, MA, Epec Engineered Technologies designs and builds custom wire harnesses for automotive, aerospace, industrial, and consumer applications. The company provides reliable, engineered solutions to meet specific client requirements, specializing in comprehensive manufacturing services for complex interconnect needs across various sectors.

Round Rock, TX

Based in Round Rock, TX, East/West Manufacturing Enterprises provides electronics contract manufacturing, including PCB assembly, box builds, and system integration. They specialize in cable and wire harness assembly for industrial, medical, automotive, and aerospace & defense markets, focusing on precision and quality.

Orange County, CA

Based in Orange County, CA, EXPERT-EMS provides comprehensive cable and wire harness assembly services. They operate as a contract electronic manufacturer (CEM) for various OEM customers, including those in the Electric Vehicle industry. The company also offers PCB assembly and box build services.

Based in Horsham, PA, Galaxy Wire & Cable, Inc. specializes in custom wire harness and cable assembly manufacturing. They offer engineering design services and can handle low minimum order requirements. The company produces a wide array of cable and wire assemblies for various industrial applications.

General Manufacturing Corp. is a contract manufacturer based in Billerica, MA, specializing in wire harness, cable, and electro-mechanical assemblies. Since 1998, they have served the industrial, robotics, medical, military, and automotive industries, providing services from prototype to production. They offer custom solutions meeting specific engineering requirements.

Findlay, OH

Based in Findlay, OH, GSW Manufacturing is a Tier 1 and Tier 2 manufacturer of custom-engineered wire harnesses. With over 30 years of expertise, the company produces high-quality wire harnesses for automotive, industrial, and recreational vehicles. GSW also provides sensors and wire harnesses to the automotive aftermarket.

Brooksville, FL

Based in Brooksville, FL, ICTC USA designs and manufactures high-quality wire harnesses for demanding industrial, aerospace, and medical environments. They provide personalized local services with global manufacturing capabilities, offering custom cable assembly, PCB assemblies, and complete electronic box builds for various growth needs.

Austin, TX

Based in Austin, TX, iRex is a custom cable manufacturer specializing in cable assemblies. The company provides comprehensive services including engineering, prototyping, tooling, testing, and production, manufacturing at scale for various product lifecycles.

Mankato, MN

Based in Mankato, MN, Kato Cable manufactures custom commercial vehicle wire harnesses and cable assembly solutions. The company provides durable electrical systems designed to power a range of vehicles, including trucks, buses, and various specialty vehicles, ensuring reliable performance for demanding automotive applications.

KSARIA Corporation provides custom, high-performance cable assemblies and wire harnesses, supported by their experienced engineering and manufacturing teams. They offer comprehensive solutions, from design to production, for a wide range of industrial and commercial applications.

Brisbane, CA

LeeMAH Electronics, based in Brisbane, CA, is a contract manufacturer specializing in custom cable assemblies and electronic manufacturing. They offer end-to-end solutions for high-mix, low-medium volume needs. The company serves the transportation industry, including electric vehicles, rail, and mass transit.

Tomball, TX

Based in Tomball, TX, M3 Distribution specializes in custom cable assemblies, wire harnesses, and electromechanical modifications. They also provide switch assemblies, fan assemblies, box builds, and Mil-Spec assemblies, serving various industrial and commercial sectors with their manufacturing capabilities.

Kingston, NY

Based in Kingston, NY, MiniProto provides wire harness manufacturing services. The company produces quality wire harnesses, from single prototypes to low-volume production runs, with typical lead times of two weeks. MiniProto focuses on delivering reliable manufacturing solutions for B2B clients.

Prysmian Group manufactures a range of electrical products, including primary automotive wire and cable, sensor cables, specialized wire harnesses, and battery cable assemblies. The company has 39 facilities across North America, emphasizing domestic manufacturing and meeting federal content standards.

El Paso, TX

Based in El Paso, TX, Northpoint Technologies, Inc. manufactures high-quality wire harnesses, custom cable assemblies, and electro-mechanical assemblies. The company also provides turnkey box and panel builds. They serve a variety of markets, including automotive, military, medical, industrial, and consumer sectors.

Morgan Hill, CA

Based in Morgan Hill, CA, NPI Solutions is an ISO 13485 certified manufacturer of custom cable assemblies and wire harnesses. Specializing in highly complex electromechanical assemblies, they provide comprehensive services from design to prototyping and final assembly for industries including semiconductor, medical, and robotics.

Santa Monica, CA

Based in Santa Monica, CA, Omega Leads, Inc. is an experienced manufacturer of custom cable assemblies and wire harnesses for OEMs. With over 55 years in business, the company serves various industries, including automotive, aerospace, and medical, utilizing state-of-the-art, robotic equipment in its US-based facilities.

Cambridge, MN

Based in Cambridge, MN, Park Manufacturing specializes in American-made custom wiring harnesses and cable assemblies. The company provides high-quality electromechanical assemblies and turnkey box builds for diverse markets. These include automotive, military, medical, industrial, consumer, and off-road applications, leveraging high automation for cost-competitive solutions.

PARPRO is a USMCA-compliant electronics manufacturing services provider specializing in custom wire harness and cable assemblies. They also provide PCB assembly, box build, and electro-mechanical assemblies. Serving industrial and Electric Vehicle sectors, PARPRO leverages tariff exemptions for cost-effective North American manufacturing and seamless trade across borders.

Austin, TX

Phoenix-Lamar Corporation specializes in custom wire harness and cable assembly manufacturing. Based in Austin, TX, they provide comprehensive solutions from design and prototyping to production runs, serving a wide range of industries including automotive, military & defense, and medical with their state-of-the-art facilities.

Garland, TX

Based in Garland, TX, Pinner Wire & Cable, Inc. specializes in manufacturing custom wire harness and cable assemblies. Since 1991, they have provided high-quality, robust solutions for diverse industries, adhering to strict standards. The company is ISO 9001:2015 certified, UL/CSA approved, and IPC/WHMA-A-620 compliant.

Des Moines, IA

Putco manufactures automotive accessories, including specialized wiring harnesses engineered for heavy-duty use. These harnesses feature robust 16-gauge wire setups and heat-resistant, hard-insulated plastic connectors, designed for durability in demanding automotive applications.

St. Louis, MO

Based in St. Louis, MO, Ric-Tronics manufactures custom cable assemblies and wire harnesses. They provide optimized electronics solutions for various industries, notably the automotive sector, focusing on connected, electric, and autonomous vehicles. Ric-Tronics delivers tailored OEM and ODM electronics built to client specifications, with quality manufacturing since 1981.

Based in Chester, PA, Ron Francis Wiring manufactures top-quality wiring harnesses, electrical components, and accessories for automotive enthusiasts. With over 45 years of experience, they provide comprehensive electrical solutions for classic cars, hot rods, muscle cars, and custom vehicles, emphasizing durability and reliability.

Racine, WI

Based in Racine, WI, RPI Harness Manufacturing designs and builds custom wire harnesses and PCBs. The company offers tailored solutions to meet exact specifications for various applications, adhering to ISO 9001-2015 quality standards.

North Salt Lake, UT

Salt Lake Cable & Harness is a custom manufacturer of wire harnesses, cable assemblies, and electromechanical assemblies. With decades of experience, the company provides prototyping and production services for both simple and complex applications. They also offer full electromechanical box build solutions.

Redondo Beach, CA

Based in Redondo Beach, CA, Senra Systems manufactures high-quality wire harnesses. The company integrates design, data, and production, utilizing technology for real-time visibility and efficient manufacturing. They offer faster lead times, supporting projects from prototypes to full-rate production with design assistance and supply chain optimization.

Speedwire Systems builds professional electrical control systems and provides custom wiring solutions for new and upgraded vehicles. With a proven record in racing applications, the company offers high-quality automotive wiring and harness fabrication, serving the performance and specialty vehicle sectors.

Auburn, WA

Based in Auburn, WA, Technical Cable manufactures custom and OEM automotive wire harnesses and cable assemblies. They offer various harness and assembly solutions, sourcing components from American suppliers or nearshore partners in Guadalajara. The company provides quick manufacturing solutions for its clients.

Bellefontaine, OH

Based in Bellefontaine, OH, The Ohio Wire Harness LLC manufactures custom wire harnesses and cable assemblies. The company prides itself on producing a high line of quality products for a wide variety of markets and applications.

Oconto, WI

Based in Oconto, WI, Amphenol Unlimited Services manufactures wire harness and cable assemblies. They support various automotive-related applications, including off-road equipment, heavy-duty trucks, specialty vehicles, and agriculture. The company offers design, prototyping, and VMI services, building products to WHMA / IPC A-620 Standard.

Dallas, TX

Wallace Electronics, a woman-owned manufacturer based in Dallas, Texas, specializes in custom cable assemblies and wiring harnesses. With over 40 years of experience, the company provides diverse solutions, including discrete wire and power cords, serving industries like automotive, medical, and industrial automation.

Spartanburg, SC

Based in Spartanburg, SC, Winar Connection is an American-owned manufacturer specializing in custom wire harnesses and cable assemblies. Established in 1982, the company provides high-quality solutions using state-of-the-art capabilities and multiple certifications, serving a wide industry base with expertise.

Santa Fe Springs, CA

Based in Santa Fe Springs, CA, M&H Electric Fabricators, Inc. manufactures automotive wire harnesses. They hand-assemble reproduction electrical products for American Muscle Cars and classic vehicles, meticulously matching original specifications for wire gauge, length, and color. Custom wire harness manufacturing services are also offered.

Fremont, CA

Based in Fremont, CA, Y.C. Cable specializes in manufacturing custom automotive cable assemblies and wire harnesses. They provide high-quality, durable, and ISO-certified solutions for EVs, hybrid cars, heavy-duty vehicles, and autonomous driving applications, tailored to specific BOM and drawings.

Suwanee, GA

Based in Suwanee, GA, Avalon Sienna specializes in manufacturing custom cable and wire harness assemblies for the automotive industry, serving OEMs and Tier 1 suppliers. They provide vertically integrated solutions for commercial and Mil-spec applications, alongside PCB assembly, sheet metal fabrication, and injection molded plastics.

Cleveland, TN

Based in Cleveland, TN, Coach Controls has over 30 years of experience building high-quality automotive wiring systems and kits. They specialize in professional wiring solutions for racing and street use, featuring Power Centers with integrated fuses and relays for efficient power distribution to all vehicle circuits.

Colorado Springs, CO

Based in Colorado Springs, CO, GVEI specializes in custom wire harness manufacturing for the automotive and heavy truck industries. They design, engineer, and produce high-quality wiring solutions, notably for Level 4/5 autonomous systems. GVEI ensures seamless communication and reliable performance for advanced driver-assistance applications.

Dallas, TX

Based in Dallas, TX, Harness Dr. designs, builds, and assembles custom automotive wiring harness solutions for enthusiasts. They provide DIY-friendly products for vehicle upgrades, including power seat, heated steering wheel, and camera extension harnesses, primarily for Chevrolet and GMC models, all manufactured in the USA.

Auburn Hills, MI

Based in Auburn Hills, MI, IET International provides prototype and low-volume wire harness fabrication services. The company also offers metal stampings and assemblies for automotive, commercial vehicle, defense, and aerospace markets. IET focuses on ensuring accurate harness production through robust testing.

Waterford, MI

Based in Waterford, MI, Netcon Enterprises, Inc. has manufactured wire harness assemblies since 1985. The ISO 9001:2015 registered and IATF 16949 compliant company offers production to service level solutions. They specialize in wire harnesses for automotive, electric vehicles, industrial, marine, and specialty vehicle applications, focusing on quality.

Carrollton, TX

Based in Carrollton, TX, Rasph Corporation provides custom wire harness and cable assemblies for automotive and recreation vehicles. Their services encompass design assistance, prototyping, and manufacturing feasibility, supporting both low-volume and high-volume production. They deliver high-quality, tailored solutions for unique customer needs.

Walled Lake, MI

Based in Walled Lake, MI, S-P Automotive LLC specializes in the modification and manufacturing of automotive wire harnesses. The company provides custom wire harnesses and plug-and-play electrical solutions, particularly for vehicles featuring modular fuse boxes. Their services include adapting existing harnesses to meet specific customer requirements.

Gary, IN

Based in Gary, IN, Wiringo manufactures custom wire harnesses and cable assemblies. The company specializes in providing tailored solutions for various sectors, including electronics, power, signal, and notably, automotive applications, serving diverse industrial needs with precision-engineered products.

ACTIA Corporation specializes in the design, manufacturing, and assembly of advanced wire harnesses and custom cable solutions. They produce on-board electronic equipment and systems for demanding ground mobility applications, serving industries like road and rail transport, agriculture, and construction.

Elgin, IL

Based in Elgin, IL, Aeromotive is a U.S. based manufacturer specializing in custom wire harnesses and OEM replacement connectors. Their automotive division serves collision centers, mechanical repair facilities, insurance companies, and aftermarket parts manufacturers. They also provide solutions for commercial and aviation/aerospace equipment.

Dallas, TX

AWC Wire, headquartered in Dallas, TX, is a custom wire harness and cable assembly manufacturer. They provide full-service manufacturing solutions for diverse applications, ranging from simple to complex multi-branch harnesses. The company serves the automotive, industrial, and aerospace sectors with multiple US manufacturing facilities.

Mckinney, TX

Based in McKinney, TX, Broach Bilt Manufacturing, Inc. is an ISO 9001 certified contract manufacturer specializing in cable and wire harness assembly services. They also provide printed circuit board assemblies (PCBAs), box builds, mechanical assembly, and test services, accommodating diverse needs from prototypes to full production.

Huntington Beach, CA

Based in Huntington Beach, CA, Beach Wire and Cable specializes in designing and manufacturing high-quality custom cable assemblies and wire harnesses. The company serves a diverse range of industries, providing extensive engineering and production capabilities for various connectivity solutions. They focus on delivering reliable custom products to meet specific client requirements.

Phoenix, AZ

Based in Phoenix, AZ, Beacon Group manufactures high-quality wire harnesses and cable assemblies. Serving equipment manufacturers, their expertise extends to agricultural, construction, industrial, medical, recreation, and transportation vehicles, as well as specialty equipment. They provide reliable electrical interconnect solutions.

Boomslang Fabrication manufactures wire harnesses, specialty cables, and custom connectors in the USA. They specialize in serving industry segments such as aftermarket engine management systems, automotive racing, off-road vehicles, and fleet retrofits. Additional expertise includes alternative fuel conversions and marine performance applications.

Fremont, CA

Headquartered in Fremont, CA, Compass Made specializes in the design, manufacturing, and assembly of custom wire harnesses and cable assemblies. They provide comprehensive services for various sectors, including the automotive, medical, industrial, and telecommunications industries. The company also offers box build and electro-mechanical assembly solutions.

Muskego, WI

Custom Wire Industries, Inc., based in Muskego, WI, is a UL and CSA certified manufacturer. They specialize in custom automotive wire harness systems, electromechanical devices, and cable assemblies. The company provides tailored electrical components and control panels for various industries, committed to 100% quality management.

Mendota Heights, MN

Based in Mendota Heights, MN, Electri-Cord Manufacturing (ECM) provides custom wiring harnesses and cable assemblies. Specializing in electronic contract manufacturing, ECM serves the automotive and transportation industry. They offer wiring solutions from simple jumpers to complex multi-breakout assemblies, utilizing their global manufacturing facilities.

Houston, TX

Gilmore Global Instruments, located in Houston, TX, manufactures custom wire harnesses and cable assemblies for mid-sized and small OEMs. Since 1994, they have provided 100% American-made harnesses for engine control and heavy equipment applications, alongside other electronics like displays and ECUs.

Based in Reading, PA, Heltronics Inc. is a contract manufacturer specializing in custom cable and wire harness designs, including solutions for tight automotive spaces. They also provide electromechanical and control panel assemblies, along with engineering support, serving industries such as automotive, aerospace, and medical.

Garland, TX

Based in Garland, TX, Hot Rod Wires, Inc. specializes in manufacturing wiring harnesses for custom and classic vehicles. They provide electrical solutions for Street Rods, Hot Rods, Classic Cars, Muscle Cars, Trucks, Jeeps, and Kit Cars, along with other 12-volt automotive applications for the aftermarket.

Rockwall, TX

Based in Rockwall, TX, Interstate Wire manufactures molded cable assemblies for various sectors. The company specializes in providing solutions for the automotive, communications, electronic, and industrial equipment industries, maintaining an ISO 9001 quality management system.

San Diego, CA

Based in San Diego, CA, OCP Group Inc. manufactures a wide range of custom wire harnesses and cables, from fine-pitch micro coaxial assemblies to 10 AWG power distribution cables. They serve industries including automation, robotics, industrial machinery, and transportation, providing quick quotes for tailored cable and harness solutions.

Fort Worth, TX

Based in Fort Worth, TX, Painless Performance manufactures and supplies automotive wire harnesses, specifically customizable chassis harnesses. The company specializes in solutions for classic cars and restoration projects, offering products like 21-circuit customizable chassis harnesses for various automotive applications.

Precision Cable Assemblies (PCA) manufactures a wide range of wire harnesses, battery cables, and custom molded cable assemblies. The company provides design, prototyping, and program management services to Original Equipment Manufacturers (OEMs) in construction, appliance, and agricultural equipment sectors.

Neenah, WI

Based in Neenah, WI, Precision Installations Inc., operating also as Precision Wire Harnesses, Inc., manufactures custom wiring and cable harnesses. They build one-off solutions with no minimum size or length, serving as a Tier 1 supplier for automotive and heavy vehicle manufacturers. The company is ISO 9001 Certified.

Portland Wiring Harness develops, designs, prototypes, and manufactures wiring harnesses for electric, hybrid, autonomous, propane, and gasoline vehicles. With over 35 years of experience, the company specializes in advanced techniques, materials, and connection integrity for the automotive industry, ensuring ITAR compliance.

Carmel, IN

Based in Carmel, IN, Telamon designs, prototypes, and manufactures automotive safety-grade wire harnesses. Their products meet rigorous automotive-grade standards, built with a zero-defect mindset for optimal reliability and safety. Telamon also provides connectivity solutions and wire harnesses for appliance applications.

Brookfield, CT

Based in Brookfield, CT, Wiring Specialties manufactures plug-and-play automotive wiring harnesses for Nissan, BMW, Datsun, Mazda, and Chevrolet chassis. They specialize in custom wiring for LS and JDM engine swaps, offering USA-made products designed for reliable performance and guaranteed startup.

Fremont, CA

Sinbon specializes in manufacturing connectivity solutions, including high-voltage battery wiring harnesses and cables for electric vehicles (EVs) and other automotive applications. Based in Fremont, CA, the company also produces wire harnesses, cable assemblies, and specialized connectors for diverse industries.

Chino, CA

VEZAMFG specializes in manufacturing custom cable and wire harness assemblies, primarily serving electric vehicle (EV) production lines. They provide tailored solutions for the automotive industry, working with leading EV manufacturers such as Lucid and Rivian. The company focuses on high-quality and reliable interconnect solutions.

Yazaki custom engineers and manufactures automotive wire harnesses, offering comprehensive power and data network solutions. They design and produce all harness components, including wires, connectors, and other electrical distribution and control elements. Yazaki supports hybrid, electric, and traditional vehicle applications.

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How to Choose a Company

  • Verify the supplier’s quality management system is certified to IATF 16949, not just ISO 9001, especially for production volumes destined for OEM or Tier 1 applications where automotive-specific process controls are non-negotiable.
  • Assess their adherence to relevant USCAR standards (e.g., USCAR-1, USCAR-2 for connector performance; USCAR-21 for ultrasonic splicing) to ensure robust electrical and mechanical integrity under demanding vehicle operating conditions.
  • Confirm their in-house testing capabilities, including pull-force testing for crimp integrity, continuity and hipot testing for electrical functionality, and environmental simulation (e.g., thermal cycling, vibration, salt spray) to validate long-term durability for specific applications.
  • Evaluate their experience with specialized wire types and processes, such as thin-wall conductors, shielded cables for EMI suppression in data lines, or high-voltage cabling for electric vehicle (EV) applications, alongside proficiency in potting or overmolding for critical sealing solutions.
  • Scrutinize their process control for critical manufacturing steps, specifically ensuring robust controls for automated wire cutting, stripping, and crimping, often indicated by statistical process control (SPC) data and rigorous operator training to IPC/WHMA-A-620 standards.
  • Clarify intellectual property and ownership of all custom tooling (e.g., crimp dies, overmolding molds) upfront; assuming you own it after paying for NRE can be a costly red flag if not explicitly documented in the master supply agreement.
  • Demand a clear understanding of their Production Part Approval Process (PPAP) and Advanced Product Quality Planning (APQP) methodology, including their capacity to provide FMEAs, control plans, and comprehensive traceability down to the raw material lot code for critical components.

Frequently Asked Questions

What specific quality certifications are essential for an automotive wire harness manufacturer?

For any production-level automotive application, IATF 16949 certification is paramount. This goes beyond ISO 9001, ensuring a robust quality management system tailored to the automotive industry's stringent demands for defect prevention, continuous improvement, and reduced waste. IPC/WHMA-A-620 also serves as a critical standard for workmanship and acceptance criteria for cable and wire harness assemblies.

How can I assess a supplier's crimping quality for high-reliability automotive applications?

Beyond visual inspection, request evidence of their crimping process controls, including regular pull-force testing results against specifications (e.g., SAE J1128 or OEM-specific), micro-section analysis capabilities, and verification that their crimp tooling (dies and applicators) is properly maintained and calibrated. Adherence to USCAR specifications for electrical connections is also a strong indicator of reliability and longevity.

What is the typical lead time for custom automotive wire harness prototypes with full PPAP documentation?

Prototype lead times can vary significantly, from 4-8 weeks for simpler designs to 12-20 weeks or more for complex harnesses requiring new tooling, specialized components, or extensive pre-production testing. Adding full Production Part Approval Process (PPAP) documentation significantly extends this, as it involves rigorous testing, data collection, and approvals across multiple levels, often adding an additional 4-8 weeks to the overall timeline, depending on the required PPAP level.

Do I need to provide my own design, or can automotive wire harness manufacturers offer design support?

Many reputable manufacturers offer extensive design for manufacturability (DFM) and design for assembly (DFA) services. While you'll typically provide initial specifications (schematics, wire lists, 3D routing models), a strong partner will review these, suggest material optimizations, routing improvements, sealing solutions (like potting or overmolding), and recommend connectors or terminals that enhance performance and reduce cost, ensuring USCAR compliance and overall system reliability.

What level of traceability should I expect for automotive wire harnesses?

For automotive applications, robust traceability is non-negotiable. At a minimum, expect lot-level traceability for all major components (wire, terminals, connectors, seals) and raw materials. For critical safety components, some OEMs may even require individual harness serialization that links back to specific production batches, test data, and material lots. Discuss this requirement early in the sourcing process and ensure it's explicitly documented in your quality agreements.

What are the considerations for suppliers manufacturing harnesses for electric vehicles (EVs)?

Manufacturing for EVs introduces specific demands, including expertise in handling high-voltage cabling (e.g., shielded, orange-jacketed wires with specific SAE J1128 or ISO 6722 ratings), specialized connectors designed for EV currents and environmental exposure, and robust thermal management. Suppliers need proven experience with high-voltage safety protocols, advanced EMI shielding for sensitive control systems, and potentially specialized potting or overmolding for battery management system (BMS) and inverter connections.

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