Drawing & BOM Review
Review wire specifications, terminals, connectors, seals, labels, protection materials, pinouts and assembly notes.
Wire Harness Manufacturing Capabilities
From Engineering Review to Tested Production
Cablum’s wire harness manufacturing capabilities include drawing and BOM review, prototype planning, wire processing, crimping, multi-branch assembly, repeat production and project-specific testing at its Shenzhen factory.
- IATF 16949 certified
- ISO 9001 certified
- Shenzhen manufacturing
- Prototype timing confirmed after requirements and materials review
Engineering & NPI Support
Review manufacturing risks before production
Engineering review covers the available drawings, BOM, component constraints, assembly risks and required inspection scope. The resulting manufacturability feedback depends on the approved project information and intended application.
DFM Feedback
Identify assembly risks, tolerance issues, component availability concerns and practical process improvements.
Prototype Planning
Define sample quantity, inspection points, validation needs and the practical prototype schedule after requirements and material availability are confirmed.
Project Workflow
A Controlled Custom Wire Harness Manufacturing Process
The exact sequence is adapted to each project, but the main control points remain consistent.
- 1
Engineering Review
Confirm drawings, BOM, application, quantities and acceptance requirements.
- 2
Prototype Build
Prepare samples using agreed materials and documented assembly requirements.
- 3
Process Validation
Verify tooling, crimp parameters, assembly sequence and inspection methods.
- 4
Pilot Production
Check production readiness and repeatability before the planned volume build.
- 5
Repeat Production
Produce repeat orders under controlled work instructions, defined inspection points and project-specific traceability requirements.
- 6
Inspection & Delivery
Complete the agreed electrical, mechanical or environmental checks and release documentation.
Production Capabilities
Flexible manufacturing for complex custom assemblies
Cablum combines automated wire processing with skilled manual assembly for prototypes, low-volume projects and repeat production.
Wire Processing
Cutting, stripping, twisting, tinning and preparation are selected according to the wire, terminal and production requirement.
Crimping & Termination
Automatic and semi-automatic crimping with documented parameters, visual inspection, crimp-height checks and pull-force verification where required. Our machines do not use integrated crimp force monitoring (CFM).
Harness Assembly
Connector insertion, branching, taping, sleeving, heat-shrink, labeling, routing and fixture-board assembly for multi-branch harnesses.
Overmolding & Protection
Custom overmolding, strain relief and sealing solutions. Mold manufacturing is coordinated through qualified external tooling partners, while cable assembly and project control remain with Cablum.
Special Processes
Soldering, ultrasonic wire splicing and shield termination can be evaluated according to conductor size, materials and application requirements.
Acceptance Criteria
Production can follow customer drawings and applicable IPC/WHMA-A-620 acceptance requirements when specified. This statement does not imply IPC company certification.
Manufacturing Overview Video
From Engineering Review to Tested Wire Harness Production
See how project inputs move through wire processing, terminal crimping, harness assembly and final inspection.
AI-assisted technical visualization for educational purposes. Actual components, tooling, production steps and inspection criteria depend on the approved project requirements.
In-House Testing
Wire Harness Inspection and Testing by Project Requirement
Electrical, mechanical and environmental tests are selected according to the product design, customer specification and applicable acceptance criteria. Test scope should be confirmed during quotation.
Electrical
- Continuity and short-circuit testing
- Pinout and wiring verification
- Insulation or withstand checks when specified
Mechanical
- Terminal pull-force testing
- Crimp-height measurement
- Bending and durability testing
Environmental
- Salt-spray testing
- UV testing
- Ingress protection testing for applicable designs
IP67/IP68 qualification: We can perform ingress-protection testing for suitable assemblies. The target rating, sample plan, test method and acceptance criteria must be defined for each project; a rating is not claimed for every product by default.
Quality Management
Documented controls, inspection and traceability
Cablum operates an IATF 16949 and ISO 9001 certified quality management system. Quality planning and records are defined according to the project and customer requirements.
Incoming inspectionMaterial and component checks according to defined requirements.
Process controlWork instructions, tooling controls and in-process inspection points.
Final inspectionVisual, dimensional and functional checks based on the agreed plan.
TraceabilityProduction and inspection records maintained according to project needs.
Documentation boundary: Cablum does not currently offer PPAP, FAI or IMDS documentation as a standard service. Please state any mandatory documentation during the initial inquiry so feasibility can be reviewed before quotation.
Typical Applications
Custom assemblies for demanding equipment
Manufacturing and test plans are tailored to the actual application rather than relying on broad industry claims.
Automotive & EV
Vehicle, battery, BMS, charging and auxiliary electrical connections.
Industrial Automation
Control cabinets, robotics, sensors, motors and production equipment.
Electronic Equipment
Signal, power and data interconnects for custom electronic systems.
Energy Systems
Custom cable assemblies for energy storage and electrical equipment.
Frequently Asked Questions
Capability questions from engineering and sourcing teams
How is prototype timing confirmed?
Prototype timing is confirmed after drawings, requirements, material availability, tooling and test scope have been reviewed. Complex tooling, uncommon components or additional testing can extend the schedule.
Does Cablum have ISO 13485 certification or a clean room?
No. Cablum is certified to IATF 16949 and ISO 9001, but does not claim ISO 13485 certification or clean-room assembly capability.
Is Cablum certified to IPC/WHMA-A-620 Class 3?
We can manufacture to customer-specified drawings and applicable IPC/WHMA-A-620 acceptance requirements when agreed. We do not present this as a company IPC certification.
Are molds manufactured in-house?
No. Mold manufacturing is handled by qualified external tooling partners. Cablum coordinates the tooling requirements and manages the cable assembly project.
Can Cablum test IP67 or IP68 cable assemblies?
Yes, ingress-protection testing can be performed for applicable designs. The rating, method, sample quantity and acceptance criteria must be agreed for each project.
Do you provide PPAP, FAI or IMDS documentation?
Not as a standard capability at present. Please disclose mandatory documentation requirements before quotation so we can determine whether the project is suitable.
Discuss Your Project
Need a Custom Wire Harness Manufacturing Feasibility Review?
Send your drawing, BOM, quantity and test requirements. Our team will review the information and respond with the next practical steps.