Custom Wire Harness
YOUR DRAWING.
OUR FIXTURE BOARD.
12-HOUR QUOTE.
Drawing-driven custom wire harness manufacturing out of our Cavite Economic Zone plant. AWG 30 to AWG 8, 4 to 1,200 nets per harness, Molex / TE / JST / Amphenol / Hirose / JAE / Sumitomo connectors alternated for cost-down inside the DFM round.
30-8
AWG Range
1,200
Max Net Count
60 N
Pull (22 AWG)
<25
Defect (PPM)
8+ Brands
Connector library
±5 N
Crimp calibration
Class 3
IPC-A-620 default
12 H
DFM turnaround
What “Custom” Means Here
DRAWING-DRIVEN.
NOT CATALOG-DRIVEN.
Roughly 92% of what leaves the Cavite plant is made-to-print custom wire harness. We do not stock a catalog of pre-made parts. Every active part number starts as a customer DXF, PDF, or DipTrace BOM, gets a 12-hour engineering response (quote plus 2-3 DFM call-outs), and routes through the same Komax KMK and Schleuniger CrimpCenter cells the rest of the line uses.
The four sibling pages — waterproof, high-voltage, overmolded, and prototype / NPI — are not separate factories. They are the same custom build with one extra constraint stacked on top. Send your drawing here when sealing, voltage and overmold are not the binding constraint; otherwise route to the matching sibling page.
Capability Block
WHAT THE CUSTOM
LINE DELIVERS.
Any Circuit Count, Any Layout
From 4-circuit signal cables to 1,200-net automotive engine-bay harnesses. Multi-branch, multi-overmold, mixed-AWG runs handled in a single fixture-board layout. The Cavite plant currently runs 380 active part numbers.
Cross-Brand Connector Library
Active stock of Molex Mini-Fit Jr/Sr, TE AMP MQS, JST PH/XH/SH, Amphenol AT/ATM, Hirose DF11/DF13, JAE MX series, and Sumitomo HX/090 housings. Terminal alternates priced inside the DFM round to cut BOM 8-14%.
Komax + Schleuniger Crimp Cells
Komax KMK 08 and Alpha 530, Schleuniger CrimpCenter 36, all four-point cross-section verified each shift. ±5 N pull-force calibration. 22 AWG terminals routinely hit 60 N pull strength against IPC Class 3 minimum 40 N.
Wire Vendor Flexibility
Lapp Olflex Classic 110, Belden 9460, Allied Wire 18-22 AWG TXL, TE Raychem 55A high-temp, and JIS-rated drag-chain cable. UL 1007 / UL 1015 / UL 1061 / UL 4703 verified across the material library.
100% Cirris Continuity Test
Every harness through Cirris CR/CH testers — continuity, dielectric, HiPot 1,500 V AC for 60 s. Test-bed throughput 480 nets per minute. Result tied to harness barcode and retained for 7 years.
PPAP Level 3 Documentation
Process flow, PFMEA, control plan, MSA, capability study (Cpk ≥ 1.33), ISIR, and IMDS for automotive. Customer-portal upload supported for VW, GM, Stellantis and Tier-1 supplier networks.
Specification Sheet
CUSTOM HARNESS
ENVELOPE.
Wire Gauge Range
AWG 30 to AWG 8 · UL 1007, UL 1015, UL 1061, UL 1569, UL 4703
Wire Vendors
Lapp Olflex, Belden, Allied Wire, TE Raychem, Sumitomo, Furukawa
Connector Brands
Molex, TE Connectivity, JST, Amphenol, Hirose, JAE, Sumitomo, Deutsch (TE)
Circuit Count
4 to 1,200 nets per harness assembly
Voltage / Current
30 V to 600 V · 0.5 A signal to 200 A battery feed
Operating Temp
−40 °C to +125 °C standard, +200 °C with TE Raychem 55A
Crimp Pull-Force (22 AWG)
60 N typical · IPC Class 3 minimum 40 N · ±5 N calibration
HiPot Test
1,500 V AC / 60 s / 0.3 mA leakage gate · 100% of units
Acceptance Class
IPC/WHMA-A-620 Class 3 default · Class 2 on request (~6% lower)
Documentation
PPAP Level 3, IMDS, RoHS, REACH, full first-article
Sample Lead Time
3-5 working days from approved drawing
Production Lead Time
7-10 days repeat · 10-15 days new build
MOQ
1 piece (NPI) · 500 (production tier) · 5,000 (volume tier)
Engineering Flow
DRAWING TO
FOB MANILA.
Drawing & DFM
Submit DXF / PDF / connector list. Engineering responds in 12 hours with quote, terminal alternates and 2-3 cost-down call-outs.
Sample Build
First-article in 3-5 working days. Cross-section, pull-force, and continuity report bundled with the sample shipment.
PPAP Approval
PPAP Level 3 generated during sample run. ISIR, control plan, and IMDS uploaded to customer portal where required.
Volume Production
Fixture-board build with poka-yoke connector keyways. CFM crimp-force monitor flags any deviation greater than 7%.
100% Test & Pack
Cirris continuity, HiPot, dielectric. Vacuum-bagged with desiccant. Serialized barcode label on each harness.
FOB Manila
MICT 30 minutes from the plant. DHL/FedEx air to LAX/JFK in 4-6 days, Maersk sea FCL in 18-22 days. Form A on every invoice.
Application Map
SIX CUSTOM HARNESS
USE CASES.
Automotive Engine-Bay Harness
12 V and 24 V chassis, sensor and infotainment runs. TE AMP MQS / 040 series, IATF 16949 PPAP3, IMDS submission included.
Industrial Control Cabinet
PROFINET, EtherCAT, IO-Link harnesses with M12 X-coded Cat 6A and 7/8-inch DC power. Drag-chain rated TPE jackets to 10M cycles.
Medical Diagnostic Cable
ISO 13485 cleanroom build. ETO and gamma compatible material library. Patient-monitor and infusion-pump assemblies.
Robotics & Cobot Backbone
10 million-cycle high-flex with JIS C 3406 tinned-copper braid. Hirose DF11 and JAE MX series for compact joint routing.
Aerospace Avionics Loom
AS9100 ruggedized build on MIL-DTL-38999 and 26482 connector families. ITAR-aware program management on request.
Renewable / Solar BESS
UL 4703 PV wire, MC4 connectorization, 600 V to 1,000 V DC battery and combiner harnesses with TS lugs.
Founder Note
“Custom does not mean expensive. The 30 minutes we spend on DFM with your drawing typically pulls 8-14% out of the BOM by alternating Hirose DF11 to JST PHR or TE Deutsch DT to Amphenol AT. That is real money on a 50,000-unit annual program.”
Mr. Fei Bo Hu
President · Xudong Group · XUDONG
Procurement FAQ
SIX QUESTIONS
BUYERS ASK.
Q.01How small a custom run will you take?
+
How small a custom run will you take?
Q.02Which connector brands can you actually source quickly versus quote-only?
+
Which connector brands can you actually source quickly versus quote-only?
Q.03Can you alternate connectors during DFM to bring price down?
+
Can you alternate connectors during DFM to bring price down?
Q.04What documentation comes with a production custom harness?
+
What documentation comes with a production custom harness?
Q.05How do you handle the Section 301 tariff issue versus a Shenzhen supplier?
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How do you handle the Section 301 tariff issue versus a Shenzhen supplier?
Q.06Can the same custom harness be built waterproof or with overmold later?
+
Can the same custom harness be built waterproof or with overmold later?
Stack These On Top
RELATED HARNESS
VARIANTS.
Waterproof Harness
Add IP67 / IP68 / IP69K sealing on the same custom drawing. +6-9% per unit, +2-3 days lead.
Read moreOvermolded Harness
Add TPE / PVC strain relief overmold. +4-7% per unit plus 600-2,400 USD tooling, one-time.
Read moreCrimping Capability
Komax + Schleuniger crimp cells, ±5 N pull-force calibration. The detail behind every harness.
Read moreWhere It Ships
CUSTOM HARNESS
VERTICALS.
Automotive & EV
IATF 16949 PPAP3, IMDS, IATF 16949 capability study Cpk ≥ 1.33 on every program.
See industryIndustrial / Factory
PROFINET, EtherCAT, IO-Link backbones. M12 X-coded Cat 6A and 7/8-inch DC power.
See industryMedical Devices
ISO 13485 cleanroom build, ETO and gamma compatible material library.
See industryCustom Builds · 2024-2026
Custom Wire Harnesses Off The Cavite Floor.
Drawing-driven, single-piece MOQ, 7-15 day lead time. A representative slice of recent custom programs.
BMS multicolor twisted-pair jumper
Battery management interconnect, 2-side connectors
Dashboard control-panel harness
High pin-count, multicolor branch leads
Shielded PH signal cable
Multi-conductor, shielded jacket, IDC ends
Real Project Snapshot · US · electrical-supply · 2024
A Build We Already Shipped In This Lane.
Scenario
A US electrical supply distributor required custom wire harnesses with specific Molex connectors, but a production batch had a dyeing/color deviation on the connector housings.
Challenge
Approximately 200 pieces of the wire harness assembly had connector coloring that did not match the strict aesthetic and technical requirements, risking rejection and project delay.
Outcome
Successfully reworked and delivered the batch without losing the client's trust; the client continued to place repeat orders in the following months without quality complaints.
Anonymized customer detail. Concrete numbers preserved verbatim.
Reviewed 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.
Free DFM review on the first round, no NDA needed. AWG 30-8, eight major connector brands in active stock, IPC Class 3 default. Quote returned within 12 hours. NDA on file. No obligation.