Custom High-Voltage
Wire Harness & Cable Assembly
Cablum provides custom high-voltage wire harnesses, shielded power cable assemblies, battery interconnects and charging system cables for EV powertrains, energy storage systems, inverters and power electronics.
Designed For Safe & Reliable Power Interconnection
High-voltage cable assemblies require careful coordination of conductor size, insulation, shielding, connector selection and mechanical protection.
Touch-Safe Options
HVIL and touch-safe connector options can be integrated according to the selected connector system and customer requirements.
EMI Shielding
Foil, braid and combined shielding options help manage electromagnetic interference in high-power electronic systems.
Thermal Performance
XLPE, silicone and other insulation options can be selected according to the required temperature and current range.
Process Verification
Finished harnesses undergo continuity, short-circuit and wiring verification before shipment.
Custom High-Voltage Cable Assembly Solutions
From battery pack interconnects to charging system cables, Cablum manufactures customized high-voltage harnesses according to customer drawings, BOM files and specifications.
EV Battery Pack Harness
High-voltage cable assemblies for battery packs, battery modules and power distribution systems.
- Orange HV cable options
- Shielded power cable
- Connector and lug integration
Motor & Inverter Cable
Shielded power cable assemblies for traction motors, inverters, converters and power electronics.
- EMI shielding options
- High-current conductor options
- Custom terminal design
Charging System Cable
Custom cable assemblies for charging systems, charging piles and onboard charging equipment.
- High-current cable options
- Connector integration
- Overmolding and strain relief
BESS Power Harness
Power and signal cable assemblies for battery energy storage systems.
- Battery rack wiring
- BMS sensing cable
- Module interconnection
HVIL Interlock Harness
Signal and interlock cable solutions for high-voltage connector systems.
- Customer-specified connector systems
- Interlock signal integration
- Custom branch routing
Custom HV Cable Assembly
Custom high-voltage harnesses manufactured according to your drawing, BOM and test requirements.
- Prototype and NPI support
- Customer-specified materials
- Volume production capability
Inside The Orange High-Voltage Cable
The cable structure can be customized according to voltage, current, temperature, shielding and mechanical requirements. Materials and dimensions are selected based on customer specifications and the final application.
Insulation Options
XLPE, silicone and other insulation options can be selected according to the required temperature and dielectric performance.
Shielding Structure
Tinned copper braid, foil and combined shielding options can support EMI management in high-power systems.
Conductor Selection
Wire gauge and conductor structure are selected according to current load, voltage drop, flexibility and installation requirements.
Connector Integration
Customer-specified high-voltage connectors, terminals, lugs and interlock components can be integrated into the final assembly.
Configured For Your High-Voltage Application
Final cable construction, connector type, shielding and protection methods are selected according to customer drawings and project requirements.
Insulation Materials
XLPE, silicone and customer-specified high-temperature insulation options.
Shielding Options
Braided shielding, foil shielding and combined shielding structures.
Protection Design
Heat shrink, sleeving, overmolding, strain relief and sealing options.
Custom Routing
Branch lengths, breakout points, mounting clips and routing geometry.
Crimping, Welding & Shield Termination
High-current connections require controlled processing, verified tooling and stable termination methods.
High-Current Crimping
Terminal crimping is performed using controlled tooling, documented parameters and batch inspection.
- Crimp height measurement
- Pull-force verification
- Tooling condition checks
Ultrasonic Welding
Ultrasonic welding options can be used for selected high-current wire splices and battery cable applications.
- Solid-state joining process
- Low-resistance connection
- Customer-specific weld design
Shield Termination
Shield braids can be terminated to connectors, ferrules or grounding points according to the electrical design.
- 360-degree shield options
- Braid and ferrule termination
- Shield continuity verification
From Engineering Review To Final Verification
Each high-voltage cable assembly is manufactured according to controlled work instructions and customer-approved specifications.
01
Engineering Review
Review drawing, BOM, voltage, current and application requirements.
02
Cable Preparation
Cutting, stripping, shielding preparation and component loading.
03
Termination
Crimping, welding, shield termination and connector assembly.
04
Protection
Heat shrink, overmolding, sleeving and strain relief.
05
Assembly
Harness routing, branch control, labels and mounting components.
06
Electrical Test
Continuity, short-circuit and wiring verification.
07
Final Inspection
Visual inspection, dimensions, labels and workmanship checks.
08
Packing & Traceability
Lot records, packaging and shipment preparation.
Verification Before Shipment
Finished high-voltage assemblies are inspected and electrically verified according to the approved production and inspection requirements.
- 100% continuity and wiring verification
- Short-circuit and miswire detection
- Crimp height and pull-force verification
- Shield continuity checks where required
- Customer-specified high-voltage or insulation testing support
General High-Voltage Assembly Options
Final ratings, materials and connector systems are selected according to customer specifications.
| Item | Available Options |
|---|---|
| Applications | EV battery packs, traction motors, inverters, charging systems, BESS and power electronics |
| Voltage Options | Customer-specified high-voltage assemblies, including projects up to 1500V DC where required |
| Cable Materials | XLPE, silicone and customer-specified high-voltage cable materials |
| Shielding | Tinned copper braid, foil, combined shielding and shield termination options |
| Connector Systems | Customer-specified high-voltage connectors, HVIL components, terminals and lugs |
| Protection | Overmolding, heat shrink, sleeving, sealing, strain relief and branch protection |
| Testing | Continuity, short-circuit, wiring verification, pull-force checks and customer-specific testing |
Where High-Voltage Harnesses Are Used
Custom high-voltage cable assemblies can be designed for different power systems, vehicle platforms and energy applications.
EV Powertrain
Battery, motor, inverter and power distribution connections.
Battery Packs
Module interconnects, rack wiring and BMS harnesses.
Charging Systems
Charging piles, onboard chargers and power modules.
Energy Storage
BESS racks, power electronics and inverter systems.
Explore Automotive & Energy Applications
See Our High-Voltage Harness Process
Watch cable preparation, crimping, ultrasonic welding, shield termination, connector assembly and electrical testing.
High-Voltage Harness FAQ
Need A Custom High-Voltage Harness?
Send us your drawing, BOM, connector requirements or test specifications. Our engineering team will review your high-voltage project and recommend a suitable cable assembly solution.