Custom High-Flex Life Harness for Robotics | Durable Overmolded Cable Solutions

1. The Challenge: Cable Failures in Robotics Applications

A Tier 1 supplier of EV charging systems required a high-voltage harness that could withstand extreme temperatures (-40°C to 105°C) and provide superior EMI shielding to prevent interference with sensitive vehicle electronics. The project was further complicated by an aggressive, time-sensitive product launch schedule and the absolute requirement for production under strict IATF 16949 standards.

2. Custom Overmolded High-Flex Cable Harness Solution

Our engineering team immediately collaborated with the client's design engineers. We proposed a comprehensive solution that addressed all key challenges:

• Material Selection: We recommended a specific combination of high-temperature resistant, automotive-grade cross-linked polyethylene (XLPE) wires and a specialized TPU overmolding compound.
• Shielding Design: We engineered a double-layered shielding design, utilizing both foil and braided shields, to provide maximum protection against electromagnetic interference (EMI).
• Process Control: We developed a dedicated manufacturing process plan, incorporating APQP and PPAP methodologies to ensure full compliance with IATF 16949 from day one.

3. Proven Implementation Process for High-Flex Robotics Cable Harness

Our dedicated New Product Introduction (NPI) team took charge of the project. We provided rapid prototypes that passed all of the client's rigorous validation tests on the first iteration, significantly de-risking the project. Throughout the tooling and trial run phases, we provided weekly progress reports and held joint review meetings, ensuring full transparency and alignment. Our in-house testing, including Hipot and pull-force testing, verified that every component met the demanding specifications.

4. Exceptional Results: 300% Lifespan Increase in Robotics Cable Harness

Our engineering-led approach and rapid execution delivered significant value to the client: