Custom Wire Harness Manufacturing
A wire harness is an organized bundle of wires, terminals, and connectors that routes power and signals inside a system. TeleWire builds custom OEM wire harnesses in Taiwan — multi-breakout, with zero-defect crimping via Komax automation — for chassis routing, control-panel integration, and high-density layouts.
Our One-Stop Custom Manufacturing Process
Send Your Drawing
Share your harness spec: wire list, gauges, branch/breakout layout, connector families, and protection (tape, loom, conduit). A diagram, BOM, or sample all work.
24h Engineering Review
Our engineers review the wiring diagram, confirm connector/terminal compatibility, and flag routing, bend-radius, or continuity risks within one business day.
Quote & Spec Confirm
You receive an itemized quote with the full BOM, wire-cut list, lead time, and an assembly print to approve before build.
Prototype Production
First-article harnesses are cut, crimped, branched, and over-taped on the same process used for production.
Testing & Verification
Every harness passes point-to-point continuity, hipot, and crimp pull-force testing, with a first-article inspection report.
Mass Production
Approved harnesses scale on IPC-trained lines with in-process (IPQC) checks and 100% continuity test.
Logistics & Delivery
Labeled, traceable shipments from our Taiwan factory, with US-based support for revisions and reorders.
How are wire harness routed & bundled?
Unlike external cables, OEM wire harnesses must navigate the complex, often extremely tight internal topography of control panels, automotive dashboards, and electromechanical chassis. We employ exact-length cutting, ultrasonic splicing, and strategic breakout points to ensure flawless installation and strain relief on your assembly line.
High-Volume Automation
We leverage automated machinery for high-speed wire cutting, stripping, and terminal crimping. This removes human variance, guarantees identical pull-force consistency, and allows us to scale production to millions of units rapidly.
Tier-1 Component Sourcing & Equivalents
Strict BOM adherence using genuine OEM connectors from Molex, JST, TE Connectivity, JAE, Amphenol, and Delphi/Aptiv. To achieve severe cost-downs without sacrificing quality, our engineering team can also source fully certified, precision-engineered 1:1 mating equivalents.
Complex Multi-Breakout Topologies
Our engineers specialize in designing wire harnesses with dozens of distinct breakout points, ensuring each connector perfectly aligns with its mating PCB or sensor without causing mechanical stress on the wire.
| Wire Harness Specification | Capability / Standard |
|---|---|
| Connector Ecosystem | Molex, JST, TE Connectivity, JAE, Amphenol (Genuine OEM or Precision Equivalents) |
| Wire Processing Range | 32 AWG (Micro) to 2/0 AWG (Heavy Power) |
| Insulation Types | PVC, XLPE, PTFE (Teflon™), Silicone, THHN |
| Binding & Routing Methods | Heat Shrink, Zip Ties, Lacing Tape, Braided PET Sleeving, Corrugated Split Loom |
| Termination Types | Ring/Spade Terminals, Quick Disconnects, IDC, Ferrule Crimping, Soldering |
Need Custom Cable Assembly or Wire Harnesses?
Working on a custom project and searching for a trusted manufacturer? Reach out to us for a rapid engineering evaluation and a detailed quote within 24 hours.
What types of wire harnesses does TeleWire Tech build?
JST Wire Harnesses
High-density, low-profile wire-to-board solutions featuring XH, SH, GH, and PH series connectors. Highly optimized for Battery Management Systems (BMS), LED arrays, and compact consumer electronics.
Molex Wire Harnesses
Utilizing genuine Mini-Fit Jr.™, Micro-Fit 3.0™, and KK® 254 series components. Ideal for high-density power distribution, server racks, and complex signal routing in consumer and industrial hardware.
Hirose (HRS) Wire Harness
Precision assemblies utilizing Hirose DF13, DF14, and U.FL series connectors. Critical for ultra-compact routing, miniature RF transmission, and space-constrained medical device chassis.
JAE Wire Harnesses
Precision interconnects utilizing genuine Japan Aviation Electronics (JAE) components like the FI-RE and MX series. Ideal for automotive infotainment, aerospace displays, and high-density PCB routing.
TE Connectivity / AMP Harness
Built for rigorous industrial and automotive applications. We expertly integrate AMPSEAL, MATE-N-LOK, and Econoseal connectors for maximum vibration, thermal, and ingress resistance.
Deutsch Heavy-Duty Harnesses
Engineered for extreme environments. We manufacture IP67/IP68 sealed assemblies using Deutsch DT, DTM, and DTP series connectors, standard in agricultural machinery, construction equipment, and heavy-duty trucks.
Phoenix Contact Wire Harness
Factory automation standard interconnects. We expertly process M8/M12 sensor cables, heavy-duty terminal block wiring, and DIN rail compatible harnesses utilizing secure push-in and screw-clamp technology.
Samtec Wire Harness
High-speed board-to-board interconnects utilizing Samtec's rugged Tiger Eye™ contacts and discrete wire systems. Guaranteed for high mating cycles and severe shock/vibration environments.
Amphenol Wire Harnesses
Ruggedized circular and MIL-DTL spec connector assemblies. Designed for heavy-duty industrial, aerospace, and telecom infrastructure requiring secure, high-retention mating and advanced EMI shielding.
LVDS Cable Assemblies
Engineered for high-bandwidth video and data transmission. We manufacture custom Low-Voltage Differential Signaling (LVDS) harnesses with strict, multi-point impedance control to prevent signal loss and EMI.
Flat Ribbon & IDC Assemblies
Mass-terminated Insulation Displacement Connectors (IDC) and flexible flat cables (FFC). Perfect for parallel data transmission, board-to-board daisy chaining, and spatially constrained chassis routing.
Crimp & Terminal Assemblies
Fully automated processing of ring terminals, spade lugs, ferrules, and quick disconnects. Every termination undergoes rigorous Crimp Force Monitoring (CFM) to ensure compliance with UL 486A-B tensile standards.
How Does TeleWire Tech Ensure Wire Harness Quality?
Electrical & Mechanical Testing
Using advanced Cirris automated test boards, every harness undergoes point-to-point continuity and short-circuit verification. We perform High Potential (Hipot) dielectric withstand testing up to 1500V to guarantee insulation integrity.
Microscopic micrography is used to verify perfectly compressed, gas-tight crimps. We actively measure crimp height, width, and wire strand compression to prevent long-term oxidation and resistance buildup.
Thermal & Spatial Routing Materials
Delivers superior abrasion resistance while maintaining extreme flexibility. Ideal for robotic joints, moving chassis components, and applications requiring heat dissipation.
Provides heavy-duty crush resistance and fluid deflection for automotive (engine bay) and harsh industrial automation environments. Available in high-temp nylon and standard polyethylene.
Adhesive-lined (meltable inner wall) polyolefin tubing creates an environmental seal and provides rigid mechanical strain relief at critical wire-to-connector transition points.
Build Your Cable Assembly
Have a drawing or a BOM? Fill out the form. Our engineers review every submission to ensure manufacturability and provide a quick quote.
Request a Quote
Wire Harness FAQs
What materials are used for wire harness bundling?
We utilize a variety of bundling materials depending on your thermal and spatial constraints. Common options include nylon zip-ties (cost-effective), expandable braided sleeving (PET for flexibility), corrugated loom tubing (for crush resistance), and MIL-spec lacing tape (for aerospace and maximum density).
Can you assist with wire harness design and reverse engineering?
Yes. If you only have a physical sample or a rudimentary schematic, our engineering team can reverse engineer the harness, create full CAD drawings, generate an optimized Bill of Materials (BOM), and provide a Design for Manufacturability (DFM) assessment to lower your production costs.
What testing protocols do you use for wire harnesses?
Every wire harness we manufacture undergoes 100% electrical testing for point-to-point continuity, shorts, and miswiring using automated Cirris test boards. For specific applications, we also perform Hipot (dielectric withstand) testing, destructive pull-force testing for crimp integrity, and TDR (Time Domain Reflectometry) for high-speed data harnesses.
Do you support high-mix, low-volume (HMLV) wire harness production?
Yes. While our automated lines are optimized for scaling into the millions, our flexible NPI (New Product Introduction) cells are structured to support high-mix, low-volume runs, rapid prototyping for complex engineering projects.