Wire Harness Manufacturing
ZERO-DEFECT
WIRE HARNESS.
FROM CAVITE.
Five harness product lines, one Cavite Economic Zone plant, one IPC/WHMA-A-620 Class 3 baseline. Custom, waterproof, high-voltage, overmolded and prototype builds run on the same Komax crimp cells and Cirris testers — there is no quality drop when you move from sample to production.
<25
Defect Rate (PPM)
7-15
Lead Time (Days)
1
Minimum Order Qty
12 H
Quote Turnaround
IPC Class 3
Default acceptance
IATF 16949
Automotive QMS
12,000 m²
Cavite floor space
MICT 30 min
Manila port distance
What We Build
ONE FACTORY, FIVE
HARNESS LINES.
XUDONG Philippines runs a 12,000 m² Cavite Economic Zone plant dedicated to custom interconnect. Five distinct product families share the same Komax KMK and Schleuniger crimp cells, the same Cirris CR/CH 100% test bay, and the same IPC/WHMA-A-620 Class 3 trained operator pool. The output split is roughly 55% automotive and EV, 18% medical and lab, 14% robotics and industrial, and 13% aerospace, solar and defense.
The product split below is not a marketing taxonomy — it is how procurement teams scope their RFQs. Pick the page that matches your dominant engineering constraint. Mixed builds (for example a waterproof high-voltage EV charging gun overmold) are routed through Custom Wire Harness with the relevant validation steps stacked on top. For DFM review before quoting, send drawings to the engineering desk.
Cross-Line Capabilities
WHAT EVERY HARNESS
GETS BY DEFAULT.
Custom Cut & Crimp
AWG 30 to AWG 8 with Komax Alpha 530 cut/strip cells, four-point cross-section every shift, ±5 N pull-force calibration. Routine 22 AWG terminal pull strength 60 N versus IPC Class 3 minimum 40 N.
IP67 / IP68 / IP69K Sealing
Heat-shrink tubing with SEALCO adhesive plus epoxy back-pot for IP69K. 96-hour salt-fog tested per ASTM B117. Validated on TE Deutsch DT, Amphenol AT and Molex MX150 housings.
High-Voltage 600 V+
Orange-jacket 600 V LV-rated assemblies for EV battery and traction motor. 1500 V AC HiPot 100% tested for 60 s with 0.3 mA leakage gate. UL 758 / UL 4703 verified material library.
Single & Double-Shot Overmolding
TPE 65–95 Shore-A and PVC 80–95 Shore-A overmold, in-house tooling rated 50,000+ flex cycles. Chemical bond to PA6 and PBT housings, 100% void-free X-ray sampling on first 50 shots.
100% Cirris Testing
Every harness on Cirris CR/CH-series testers: continuity, dielectric and HiPot, serialized to barcode. Test-bed throughput 480 nets per minute, audit data retained 7 years.
NPI to Volume in One Site
Prototype-to-production handoff stays inside the same Cavite plant — no tooling rebuild, no team transition. First article in 3-5 days, PPAP Level 3 included on request.
Specification Sheet
TECHNICAL
ENVELOPE.
The numbers below describe what the Cavite line builds today, not what it could build with extra capex. Anything outside this envelope routes through DFM review for confirmation.
Wire Gauge Range
AWG 30 – AWG 8 (UL 1007, UL 1015, UL 4703, Lapp Olflex, Belden, TE Raychem)
Voltage Rating
30 V signal · 300 V control · 600 V LV · 1,000 V DC orange-jacket
Operating Temperature
−40 °C to +125 °C standard, +200 °C with TE Raychem 55A wire
IP Rating
IP54, IP67, IP68 (1 m / 30 min), IP69K spray-down
Connector Brands
Molex, TE Connectivity, JST, Amphenol, Deutsch (TE), Hirose, JAE, Sumitomo
Crimp Pull-Force (22 AWG)
60 N typical · IPC-A-620 Class 3 minimum 40 N · ±5 N calibration
HiPot Test
1,500 V AC / 60 s / 0.3 mA leakage limit · 100% of units
Salt-Fog Validation
ASTM B117 96 h on every new IP-rated program
Flex Life (Robotic)
10 million cycles JIS C 3406 tinned-copper braid
Default Acceptance Class
IPC/WHMA-A-620 Class 3
MOQ
1 piece (NPI) · 500 (production tier) · 5,000 (volume tier)
Lead Time
Sample 3-5 days · Repeat 7-10 days · New build 10-15 days
Certifications
IATF 16949, ISO 9001:2015, ISO 13485, IPC/WHMA-A-620, UL Recognized, RoHS, REACH
Five Product Lines
PICK THE CONSTRAINT,
WE BUILD THE HARNESS.
Custom Wire Harness
Drawing-driven assemblies from 4-circuit signal cables to 1,200-net engine-bay harnesses. Molex, TE, JST, Amphenol, Hirose, JAE — fully alternated for cost-down.
Read specWaterproof Harness
IP67, IP68 (1 m / 30 min) and IP69K spray-down for marine sensors, EV charging guns, outdoor IoT and food-grade equipment. Validated to ASTM B117 96 h salt fog.
Read specHigh-Voltage Harness
600 V to 1,000 V DC orange-jacket assemblies for EV battery packs, traction inverters and DC-fast-charge stations. HiPot 1500 V AC 100% tested.
Read specOvermolded Harness
TPE / PVC strain reliefs and full overmolds, 50K-cycle flex life. Single and double-shot tooling cut in our own mold shop in 18-25 days.
Read specPrototype / NPI
MOQ 1, first article in 3-5 working days. Free 24-hour DFM review, no NDA required for the initial quote round. Built on the same line as production.
Read specFrom RFQ to FOB Manila
SIX STEPS, ONE
FACTORY OWNER.
RFQ + DFM Review
Send drawing or connector list. Engineering desk responds in 12 hours with quote, DFM call-outs and recommended terminal alternates from Molex / TE / JST.
First-Article Sample
Sample built in 3-5 working days on a Komax KMK crimp cell with the same operator who will run production. Cross-section report and pull-force log included.
PPAP / FAI Submission
PPAP Level 3 documentation: process flow, PFMEA, control plan, MSA, capability study (Cpk ≥ 1.33), and ISIR. Customer-portal upload supported.
Volume Build
Production on fixture boards with poka-yoke connector keyways. Inline crimp-force monitoring (CFM) flags any deviation greater than 7% on every terminal.
100% Electrical Test
Every harness through Cirris CR/CH for continuity, dielectric and HiPot. Serial number printed on the harness label and tied to the test result for 7 years.
Pack & Ship
Vacuum-bagged with desiccant. FOB Manila via MICT, 30 min from the plant. DHL/FedEx air to LAX/JFK in 4-6 days, Maersk sea in 18-22 days.
Applications
WHO BUYS THESE
HARNESSES.
Automotive & EV
IATF 16949 lines for EV battery packs, dashboard, sensor and chassis harnesses. PPAP Level 3, IMDS submission, 13-week capacity reservation.
See industry →Medical Devices
ISO 13485 cleanroom build for diagnostic, infusion-pump and patient-monitor cables. ETO and gamma compatible material library.
See industry →Robotics & Automation
10 million-cycle high-flex cables for cobots, AGVs and AS/RS systems. M12 X-coded Cat 6A for PROFINET and EtherCAT backbones.
See industry →Industrial / Factory
PROFINET, EtherCAT, IO-Link, and 7/8-inch DC-power harnesses. Track-chain rated TPE jackets and corrugated loom protection.
See industry →Aerospace & Defense
AS9100 ruggedized assemblies on MIL-DTL-38999 and 26482 connector families. ITAR-aware program management, US person controls available.
See industry →Solar & Energy
UL 4703 PV wire, MC4 / Stäubli connectorization and DC battery-storage harnesses. 1,500 V DC string and combiner assemblies.
See industry →Founder Note
“Five product lines look like five factories from the outside. Inside they are one Cavite floor, one IPC Class 3 operator pool, and one Cirris test bay running 480 nets per minute. The 25 PPM defect rate is not per line — it is the single number coming out the door.”
Mr. Fei Bo Hu
President · Xudong Group · XUDONG
Buyer FAQ
SIX QUESTIONS
WE ANSWER WEEKLY.
Q.01What is the difference between custom, waterproof, high-voltage and overmolded harnesses?
+
What is the difference between custom, waterproof, high-voltage and overmolded harnesses?
Q.02What is your MOQ and how does pricing scale?
+
What is your MOQ and how does pricing scale?
Q.03Which IPC class do you build to by default?
+
Which IPC class do you build to by default?
Q.04How does the Cavite Economic Zone tariff advantage work for US importers?
+
How does the Cavite Economic Zone tariff advantage work for US importers?
Q.05Can you handle prototype, low-volume and production in the same factory?
+
Can you handle prototype, low-volume and production in the same factory?
Q.06What makes a Cavite harness manufacturer different from a Shenzhen one?
+
What makes a Cavite harness manufacturer different from a Shenzhen one?
Related Services
ADJACENT
CAPABILITIES.
Box Build Assembly
Cable + enclosure integration up to 1,200 components. Single PO, single timeline, single point of accountability.
Read moreTooling & Mold
In-house injection-mold and overmold tooling, 18-25 day cut-to-first-shot. Tool ownership stays with the customer.
Read moreTesting & Inspection
Cirris CR/CH testers, HiPot, dielectric, IPX validation chambers. 100% test, serialized result for 7 years.
Read moreTop Verticals
WHERE THESE HARNESSES
SHOW UP MOST.
Automotive & EV
IATF 16949 lines for EV battery packs, dashboard, sensor and chassis harnesses. PPAP Level 3, IMDS submission, 13-week capacity reservation.
See industryRobotics & Automation
10 million-cycle high-flex cables for cobots, AGVs and AS/RS systems. M12 X-coded Cat 6A for PROFINET and EtherCAT backbones.
See industrySolar & Energy
UL 4703 PV wire, MC4 / Stäubli connectorization and DC battery-storage harnesses. 1,500 V DC string and combiner assemblies.
See industryReviewed by Hommer Zhao- Cavite-based wire harness engineer at XUDONG, IPC/WHMA-A-620 Class 3 trained, 8+ years in automotive & medical harness manufacturing.
Next Step
Send The Drawing. We Reply In 12 Hours.
Tell us which of the five harness lines you need — or send the spec and we will route it. PPAP Level 3, IPC Class 3 and tariff-free Cavite shipping included. Quote returned within 12 hours. NDA on file. No obligation.