https://www.cable-sf.com/Custom-New-Energy-Harness.html
Our factory enjoys a distinct edge in customizing high-voltage wiring harnesses for new energy vehicles. Boasting a senior professional team, advanced manufacturing techniques, a rigorous quality control system, and a high-level commitment to environmental protection and safety, we can offer highly individualized solutions to ensure that products not only precisely align with customer demands but also conform to international certification standards. To bring efficient, safe and reliable wiring harness products to customers.
The use of high-quality insulation materials, high temperature resistance, corrosion resistance, to ensure stable operation in extreme environments and pure copper wire is selected to reduce energy loss and improve power transmission efficiency.
Equipped with various connectors, compatible with a variety of new energy models and According to customer needs, provide one to one customized all kinds of wiring harness products and services.
Custom New Energy Harness
As a trusted new energy wiring harness supplier, we present our custom new energy harness solution designed for electric vehicles, energy storage systems, charging stations, and related new energy equipment. This wiring harness system supports both high-voltage power transmission and low-voltage control/signal lines, offering a one-stop, fully tailored solution to meet diverse project requirements.
New Energy Wiring Harness Key Features & Benefits
High Voltage & Safety Design
Utilizes high-grade insulation materials (e.g. XLPE, TPE, fluoropolymer) to withstand elevated temperatures and voltage stress
Meets or exceeds required dielectric strength with robust insulation thickness and rigorous voltage-withstand testing
Incorporates creepage/clearance design, shielding, and grounding paths to ensure electromagnetic compatibility (EMC) and system safety
Tailored Customization
Fully custom wiring layout based on your schematics: wire lengths, branch points, connectors, wire gauges, shielding, bundle structure, color coding, labeling
Wide compatibility with mainstream connector types (e.g. Deutsch, TE, Amphenol, IP-rated, waterproof plugs)
Support for variant versions (e.g. different lengths, branch count, power ratings) with repeatability
Quality Assurance & Testing
Every harness is 100% tested with continuity, insulation resistance, and dielectric / high-voltage (hipot) tests
Optional environmental reliability tests (thermal cycling, vibration, salt spray, humidity) per customer requirements
Full traceability on wire batches, components, production logs
Regulatory & Material Compliance
Non-toxic materials for safe operation
Design for Manufacturability & Serviceability
Modular segments and service loops for easy maintenance or replacement
Clear and permanent labeling of each branch and end for installation convenience
Strain relief, protective sleeves, tubing, clamps to protect wires from abrasion and stress
Typical Applications
Main wiring harness and sub-harnesses for electric vehicles
Battery pack interconnect harnesses (BMS to modules)
High-voltage to motor / inverter / charger harnesses
Energy storage system wiring between modules, racks, converters
Charging station internal harnesses
Photovoltaic / solar power system wiring bundles
Various control, sensor, and communication wiring in new energy equipment
Because we specialize in new energy wiring harness development, we understand the challenges in durability, safety, and system integration in these environments.
Customization & Ordering Process
Requirement Submission
Send us your wiring diagram, connector types, wire gauges, branch layout, environment constraints, quantity, and any special test requirements.
Design Proposal & Quotation
Our engineering team reviews and optimizes wiring layout, calculates voltage drop, suggests materials, then issues a formal drawing and quote.
Sample Fabrication & Validation
We build sample harness(es) for your testing — electrical performance, fit & form check, environmental tests.
Mass Production
On sample approval, we proceed to volume production under controlled quality processes.
Final Testing & Delivery
Each batch undergoes full QC testing, labeling, packaging, and shipment. We also offer post-delivery technical support.
Why Choose Us
Focused expertise as a new energy wiring harness supplier
Strong R&D capability and experience in high-voltage / hybrid / battery interconnect systems
Rigorous quality management and component traceability
Flexible customization from prototype to high-volume
On-time delivery, global logistics support, and responsive after-sales service
Packaging & Shipping
Individual harnesses are packaged with protective wrapping, labels, anti-static and moisture-proof bags
Bundles secured to avoid damage during transit
Shipping options: air freight, sea freight, express courier — arranged per your location and urgency
FAQ
Q: How do you ensure harness reliability?
A: We test every harness electrically, optionally run environmental stress tests, and maintain strict manufacturing controls.
https://www.cable-sf.com/Custom-New-Energy-Harness.html
Dongguan Shuofeng Electronics Co., Ltd.