Waterproof Wire Harness
IP67. IP68.
IP69K SPRAY-DOWN.
96 H SALT FOG.
Sealed wire harnesses for marine sensors, EV charging guns, outdoor IoT and food-grade washdown lines. TE Deutsch DT, Amphenol AT and Molex MX150 connector libraries in active stock at our Cavite plant. Validation runs in-house — no third-party lab queue.
IP69K
Top Rating
96 H
Salt Fog (B117)
−40 / +125
Operating °C
1 M / 30 MIN
IP68 Immersion
IP67/68/69K
Sealing range
ASTM B117
Salt fog method
0.3 mA
Leakage gate
Class 3
IPC-A-620 default
What “Waterproof” Means Here
IP RATING IS THE FLOOR.
FIELD LIFE IS THE CEILING.
IEC 60529 IP ratings describe a 30-minute lab test. A waterproof harness that passes IP67 in the lab can still corrode in the field if the wire seal size is wrong, the cable jacket loses elasticity at −20 °C, or the connector backshell has a tooling-line micro-channel. The Cavite line builds against actual environmental envelopes: temperature swing, UV exposure, chemical contact and flex count — not just the IP digit.
For builds where sealing is the dominant constraint, this is the right page. If your harness is also high-voltage, see high-voltage harness — we stack the two specs. If the sealing is delivered through a TPE overmold rather than a connector seal, route via overmolded harness. For the unconstrained custom baseline, see custom wire harness.
Sealing Capability Block
THREE TIERS OF
SEAL, ONE LINE.
Three Sealing Tiers (IP67 / IP68 / IP69K)
IP67 dust-tight + 1 m immersion 30 min for outdoor IoT and chassis sensors. IP68 with extended immersion for marine bilge and submersible pumps. IP69K spray-down (80 °C / 100 bar / 30 cm) for food-grade and pharma washdown lines.
96-Hour ASTM B117 Salt Fog
Every new IP-rated program validated to ASTM B117 96 hours minimum, 240 hours on request. Pass criterion is zero corrosion product on the terminal interface and zero electrical resistance change greater than 5%. Failure rate over the last 18 months: 1.2%.
Sealed Connector Library
Active stock: TE Deutsch DT / DTM / DTP, Amphenol AT / ATP / ATM, Molex MX150 / MX64 / Squba, JST WPJ / WPK, Sumitomo HX-090 / 187 sealed series. Cable seals, interfacial seals and rear-mount boots paired and torque-spec sheet on file.
Sealing Methods Stack
Heat-shrink with SEALCO adhesive 1:3 ratio for IP67 transitions. Two-part epoxy back-pot for IP68 connector entries. Liquid-injection molded TPE overmold for IP69K. All three methods on the same line, selected by environmental spec — not by what is convenient.
Validation Chambers In-House
ESPEC SH-262 salt fog cabinet, custom IPX water-jet test rig (IPX5/6/9K), and a 1.5 m immersion tank for IP68 verification. Validation runs cost is included on first article — no “send to a third-party lab” delay.
1,500 V AC HiPot 100% Tested
Every waterproof harness through Cirris with 1,500 V AC for 60 s, 0.3 mA leakage gate. Catches the one in 8,000 unit where a microscopic seal pinhole would otherwise survive a dry continuity test and fail in the field.
Specification Sheet
WATERPROOF
ENVELOPE.
IP Ratings
IP54, IP67, IP68 (1 m / 30 min and extended), IP69K (80 °C / 100 bar / 30 cm)
Wire Gauge
AWG 26 to AWG 8 · UL 1015, UL 4703, TE Raychem 55A high-temp
Operating Temperature
−40 °C to +125 °C standard · +200 °C with TE Raychem
Sealed Connectors
TE Deutsch DT/DTM/DTP, Amphenol AT/ATP, Molex MX150/Squba, JST WPJ/WPK, Sumitomo HX-090
Sealing Methods
Heat-shrink + SEALCO adhesive · two-part epoxy back-pot · liquid-injection TPE overmold
Cable Jackets
TPE 65-95 Shore-A, PVC 80-95 Shore-A, PUR 90 Shore-A for marine
Salt-Fog Validation
ASTM B117 96 h default · 240 h on request · zero >5% resistance shift criterion
Immersion Test
1.0 m for 30 min (IP68) · custom depth and duration on quote
Spray Test
IPX5 (12.5 L/min, 3 m), IPX6 (100 L/min, 3 m), IPX9K (14-16 L/min, 80 °C, 100 bar)
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
Lead Time
Sample 5-7 days (validation included) · Production 10-15 days
MOQ
1 piece (NPI) · 500 (production tier) · 5,000 (volume tier)
Validation-First Flow
SPEC TO
FOB MANILA.
Spec Sheet & DFM
Send environmental envelope (IP rating, temp, immersion depth, chemicals). Engineering replies in 12 h with quote and recommended sealing method.
Material Selection
Sealed connector and gasket material chosen against IP target. PUR for marine UV exposure, TPE for general outdoor, FKM for chemical resistance.
Sample + Validation
First article in 5-7 days, includes 96 h salt fog and IPX immersion test report. No third-party lab delay — chambers are on site.
Production Build
Heat-shrink with calibrated 350 °C heat tunnels, epoxy potting in vacuum chamber, TPE overmold on dedicated 50T press. Operator has IPC-620 Class 3 + sealing addendum.
100% HiPot + Sample IP
Cirris 1,500 V AC HiPot on every unit. AQL 1.0 immersion test on every production lot — random pull, full tank.
Pack & Ship
Vacuum-sealed with desiccant. FOB Manila, MICT 30 min away. Form A on every invoice for tariff-free US entry.
Application Map
SIX WATERPROOF
USE CASES.
Marine Sensor & Bilge Pump
IP68 PUR-jacket harnesses with TE Deutsch DT04 and DT06 mating pairs. UV-stable TPE overmolds, 240 h salt fog validated for coastal racks.
EV Charging Gun (CCS / CHAdeMO)
IP67 mating + IP55 retracted. Liquid-cooled cable variants on quote. UL 2251 and IEC 62196 sealing geometry.
Outdoor IoT / Smart City
IP66/67 enclosure-mount harnesses for cellular gateways, lidar masts, and traffic sensors. Lapp Olflex Robust outdoor cable, M12 X-coded backbone.
Food & Beverage Washdown
IP69K rated for 80 °C / 100 bar washdown with 30 cm distance. FDA-grade TPE jacket, stainless backshell, NSF-compliant interfacial seal.
Solar / BESS Outdoor
UL 4703 PV wire, MC4 / Stäubli connectorization, 1,500 V DC string and battery harnesses tested for 25-year UV plus humidity cycling.
Construction & Off-Highway
IP69K cabin and engine harnesses for excavators and ag tractors. Deutsch DT and Sumitomo 090 sealed series, drag-chain rated jackets.
Founder Note
“The IP digit is the easy part. What kills field reliability is the wrong cable-seal size on a TE Deutsch DT — pass the lab, fail at month nine. We size every seal against actual jacket OD tolerance, not the spec sheet. That is why our 96 h salt fog first-pass rate sits at 98.8%.”
Mr. Fei Bo Hu
President · Xudong Group · XUDONG
Sealing FAQ
SIX QUESTIONS
ENGINEERS ASK.
Q.01How do I pick between IP67, IP68 and IP69K?
+
How do I pick between IP67, IP68 and IP69K?
Q.02Is 96 hours of ASTM B117 salt fog enough?
+
Is 96 hours of ASTM B117 salt fog enough?
Q.03What sealing methods do you use and how do you pick?
+
What sealing methods do you use and how do you pick?
Q.04Can you do IP-rated builds at NPI quantities?
+
Can you do IP-rated builds at NPI quantities?
Q.05Which sealed connector brands ship reliably from Cavite?
+
Which sealed connector brands ship reliably from Cavite?
Q.06Can the harness be both waterproof and high-voltage?
+
Can the harness be both waterproof and high-voltage?
Stack These On Top
RELATED HARNESS
VARIANTS.
Overmolded Harness
TPE / PVC liquid-injection overmold — the cleanest path to IP69K and 50K-cycle flex life.
Read moreHigh-Voltage Harness
600 V to 1,000 V orange-jacket EV and BESS harnesses with 1,500 V AC HiPot 100%.
Read moreTesting & Inspection
ESPEC SH-262 salt fog, IPX9K spray rig and 1.5 m immersion tank — all on site, no lab queue.
Read moreWhere It Ships
WATERPROOF HARNESS
VERTICALS.
Automotive & EV
EV charging, body sensors, undercar harnesses. IP67 chassis, IP68 cooling-loop, IP69K wash-bay.
See industrySolar & Energy
UL 4703 PV wire, MC4 connectorization, 25-year UV plus humidity-cycle validated.
See industryIndustrial / Factory
IP69K washdown for food, pharma, beverage. M12 X-coded backbones for outdoor automation.
See industryIP67 / IP68 Builds
Waterproof & Sealed Harnesses · IP67 Verified.
Submersible test on every new program. Panel-mount sealed receptacles, braided EMI jackets, IP67 connector partners.
Waterproof panel-mount receptacle
IP67 sealed, captive cover boot
Braided test leads · banana + USB
Braided EMI shield, sealed terminations
JST + Molex twisted jumper
Short overmolded sealed jumper
Real Project Snapshot · US · marine · 2025-Q3 → 2026-Q1
A Build We Already Shipped In This Lane.
Scenario
A US marine OEM sought a new supplier for custom wire harnesses and audio systems, initiating a rigorous multi-month evaluation process involving multiple business units.
Challenge
The customer issued 6 separate RFQs over two months and engaged in a 64-email deep-dive technical thread, demanding strict weekly delivery, tariff mitigation, and cost competitiveness compared to incumbent suppliers.
Outcome
Successfully navigated the extensive qualification process, secured the tooling order, and transitioned into the prototyping phase for mass production.
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 Spec. We Validate In-House.
IP67, IP68 or IP69K — same Cavite line, same 96 h salt fog gate. Sample shipment includes the validation report. Quote returned within 12 hours. NDA on file. No obligation.