Capability · CAP-03
Testing.
100% Cirris. ZERO SAMPLING.
Eight Cirris benches. 100% continuity, open, short, miswire on every net of every harness. 1500 V AC HiPot for 60 s with 0.5 mA leakage limit. Plus an in-house environmental lab — salt-fog, thermal shock, IP67/IP68, 10M flex, MIL-STD-810G vibration.
100%
Test Coverage
Every harness
1500V
HiPot AC
60s @ 0.5mA leak
≥100MΩ
Insulation
@ 500VDC UL 758
96h
Salt-Fog
ASTM B117 chamber
Cirris
CR-easy + CH2
8 test benches
JESD22
Thermal Shock
-40/+85 × 100 cycles
IP67/68
Immersion
1m × 30min validated
MIL-STD-810G
Vibration
10–2000 Hz random
What Test Means Here
Every Net.
Every Harness.
Every Time.
XDPI's test floor is built around a single rule: every harness leaves the building with a Cirris pass log against its serial barcode. We don't sample. We don't accept “the first 50 looked good”. Eight Cirris benches (6 × CR-easy + 2 × CH2) sweep every net for continuity (<10 mΩ), open, short, miswire and intermittent. A 142-net automotive harness scans in roughly 11 seconds.
Beyond electrical, we run an in-house environmental lab — salt-fog (Q-FOG SSP, ASTM B117, 96 h), thermal shock (-40 / +85 °C × 100 cycles, JESD22-A104), IP67/IP68 immersion to IEC 60529, 10 M flex cycles per IEC 60068-2-31, vibration 10-2000 Hz random per MIL-STD-810G §514, drop test ISTA 6-Amazon. AEC-Q200 1000-cycle thermal is available for automotive PPAP.
Test data ties to crimping CFM logs and solder FQC sign-offs through the harness serial barcode in MES. PPAP Level 3 includes Cpk study, leakage histograms, and operator cert log. Heavily used on HV harnesses and waterproof harnesses where IP and dielectric matter most.
Six Test-Bench Dimensions
What The Bench Catches.
Cirris CR-easy + CH2 Benches
Eight Cirris benches: 6× CR-easy for low/mid pin-count harnesses, 2× CH2 for HV programs (up to 1500 VDC HiPot, 5000V AC dielectric). Each bench loop-back verified at every shift change.
TST-01
100% Continuity, Open, Short
Every harness — every net — tested for continuity (<10 mΩ), open, short, miswire, and intermittent (vibration probe). No statistical sampling. Pass/fail logged with serial barcode to MES.
TST-02
1500 V AC HiPot · 60 s
Hi-Potential dielectric withstanding test per IPC-9252: 1500 V AC RMS for 60 s, leakage limit 0.5 mA. Flagged harnesses re-tested after dwell; no auto-pass on retry.
TST-03
Insulation Resistance ≥100 MΩ
IR test at 500 VDC per UL 758 — minimum 100 MΩ across all isolated nets. Used in addition to HiPot for medical and aerospace cables to detect partial-breakdown defects.
TST-04
Environmental Lab
On-site salt-fog chamber (Q-FOG SSP per ASTM B117), thermal shock chamber -40/+85 °C × 100 cycles per JESD22-A104 Cond. C, IP67/IP68 immersion tank, dust chamber per IEC 60529.
TST-05
Mechanical Stress
10 M flex-cycle bend test per IEC 60068-2-31 (Igus chainflex compliant). Vibration 10-2000 Hz random per MIL-STD-810G §514. Drop test per ISTA 6-Amazon for last-mile durability.
TST-06
Technical Specifications
Test Lab Datasheet.
| Continuity Test | 100% — every net, every harness, <10 mΩ pass |
| Open / Short / Miswire | 100% — Cirris CR-easy or CH2 |
| HiPot AC Dielectric | 1500 V AC RMS, 60 s, 0.5 mA leakage limit per IPC-9252 |
| HiPot DC (HV programs) | Up to 5000 V DC on Cirris CH2 |
| Insulation Resistance | ≥100 MΩ at 500 V DC per UL 758 |
| Intermittent Detect | Vibration probe with 10 µs sample rate |
| Salt-Fog | ASTM B117 · 5% NaCl · 35 °C · 96 h continuous |
| Thermal Shock | -40 / +85 °C × 100 cycles · JESD22-A104 Cond. C |
| Thermal Cycle | -40 / +125 °C × 1000 cycles available · AEC-Q200 |
| IP Rating | IP67 (1m × 30 min) and IP68 (continuous immersion) per IEC 60529 |
| Flex Life | 10 M cycles per IEC 60068-2-31 (chainflex test rig) |
| Vibration | 10–2000 Hz random per MIL-STD-810G §514, swept-sine per IEC 60068-2-6 |
| Drop / Shock | ISTA 6-Amazon, MIL-STD-810G §516 (40g half-sine) |
| Dust | IEC 60529 IP6X talc chamber |
| Test Bench Count | 8 Cirris (6× CR-easy + 2× CH2) |
| Data Retention | Cirris log + MES record · 7 years per IATF §7.5.3 |
Test Sequence
Six Steps. Two Operators.
One Serial Barcode.
Bench Setup
Operator loads program by harness P/N from MES; Cirris bench self-checks loop-back fixture and dielectric tower. Pass slip required before first piece.
Continuity + Open/Short
Every net swept for <10 mΩ continuity, open, short, miswire — typical 142-net automotive harness scans in 11 s on CR-easy.
HiPot Dielectric
1500 V AC ramp at 100 V/s, hold 60 s, leakage measured to 0.5 mA limit per IPC-9252. Failures locked in fixture; quarantined for engineering review.
IR Verify (selected)
Medical and aerospace harnesses get an additional 500 V DC IR test; ≥100 MΩ pass per UL 758. Used to catch partial-breakdown defects HiPot misses.
Serialize + Log
Cirris result (PASS/FAIL with detailed net log) writes to MES against the harness serial barcode. Operator initials, bench ID, timestamp captured.
FQC Microscope
10× Olympus microscope inspection of every solder joint and crimp transition per IPC-A-620 §10. Different operator from the Cirris bench operator.
Where Test Data Goes
Six Test Application Buckets.
PPAP-3 Automotive
100% Cirris + capability study (Cpk ≥1.67) on continuity resistance for IATF 16949 PPAP submissions.
Medical Device
1500V AC + 500V DC IR per UL 60601-1 dielectric requirements for patient-applied parts.
EV / Solar HV
Up to 5000V AC dielectric on Cirris CH2 for HV battery packs and PV string harnesses.
Robotics 10M-Cycle
Igus chainflex-compatible bend rig validates 10 M flex cycles per IEC 60068-2-31 before PPAP.
MIL-STD Vibration
10–2000 Hz random per MIL-STD-810G §514 + 40g shock per §516 for ruggedized assemblies.
IP67/IP68 Outdoor
Immersion + dust chamber qualification per IEC 60529 for outdoor industrial and PV harnesses.
Founder Note · Mr. Fei Bo Hu
“The reason we run 100% Cirris instead of AQL sampling is simple math. Eleven seconds of bench time on a 142-net harness costs us pennies. One returned shipment costs the customer their line. The day a buyer asks me ‘why 100%?’ I show them the Cirris log file size — it's the cheapest insurance you can buy in this industry. The environmental lab is the same logic — you can rent salt-fog hours, but you can't rent the engineer who reads the photos.”
— Mr. Fei Bo Hu · President · Xudong Group · XUDONG Philippines
Test Engineering FAQ
Six Questions
Buyers Always Ask.
Q.01Why test 100% when the AQL allows sampling?
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Why test 100% when the AQL allows sampling?
Q.02What's the difference between HiPot and Insulation Resistance, and when do you run both?
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What's the difference between HiPot and Insulation Resistance, and when do you run both?
Q.03How tight is your continuity threshold and is it good enough for low-current signal cables?
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How tight is your continuity threshold and is it good enough for low-current signal cables?
Q.04Can you run salt-fog, thermal shock, and IP67 in-house or do you outsource?
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Can you run salt-fog, thermal shock, and IP67 in-house or do you outsource?
Q.05How does test data tie back to PPAP and your customer audit trail?
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How does test data tie back to PPAP and your customer audit trail?
Q.06What happens to a harness that fails Cirris?
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What happens to a harness that fails Cirris?
Real Project Snapshot · US · electrical-supply · 2024 → 2026
A Build We Already Shipped In This Lane.
Scenario
A US electrical supply distributor needed a repeat order of wire harnesses on an accelerated timeline to support their downstream client's project recovery.
Challenge
Standard lead times were too long; the client needed delivery within 3 weeks, but budget constraints meant they could not afford expediting fees.
Outcome
On-time delivery within the 3-week window without additional cost to the client, securing the ongoing repeat program and strengthening the partnership.
Anonymized customer detail. Concrete numbers preserved verbatim.
Next Step
See A Cirris Log Before You Place A PO.
Send us your harness drawing. We'll fixture it, run a sample build, and return the full Cirris log + 10× FQC photos within 7 working days. Quote returned within 12 hours. NDA on file. No obligation.