Custom Automotive Wire Harness Manufacturer | OEM Cable Assembly

Core Automotive Products

Automotive Harness Solutions by Vehicle System

From EV powertrain systems to ADAS sensor networks and cabin electronics, Kaweei develops automotive wire harness solutions tailored to specific vehicle architectures and OEM requirements.

Commercial Vehicle Wiring Harness

Durable heavy-duty harnesses for trucks, buses and construction machinery, resistant to vibration, mud and wide temperature fluctuations.

Voltage: 12V / 24V Low Voltage
Compliance: IATF 16949, ISO 6722

ADAS & Sensor Integration

From heavy-duty wiring harness for trucks to ADAS sensor networks and cabin electronics, Kaweei develops automotive wire harness solutions tailored to specific vehicle architectures and OEM requirements.

Speed: High-Speed Data
Grade:Automotive Grade

Dashboard & Cabin

Compact harnesses for instrument clusters and HVAC. Modular design for serviceability.

Design: Modular Architecture
Application: Cluster, HVAC

Engineering Capability

Automotive Connector & Wire Expertise

We offer full OEM matching for mainstream automotive connector brands and region-specific certified wiring materials compliant with ISO 6722 & IATF 16949. Our engineering team provides customized DFM analysis, terminal validation and material selection matched to your vehicle’s system, operating temperature and regional manufacturing standards.

OEM Connector Platform Experience

Brand	Typical Application
TE Connectivity	Low-voltage vehicle power distribution, ADAS sensing modules, cabin control & chassis wiring harnesses
Yazaki	Full OEM vehicle body wiring, door module assemblies, interior infotainment signal cables
Sumitomo	Passenger car signal & power networks, instrument cluster and sensor interconnects
Deutsch	Commercial vehicle, off-road machinery heavy-duty low-voltage wiring systems
Molex	Automotive infotainment, compact ECU electronics and small sensor wiring assemblies

Automotive Wire Types

Wire Type Category	Representative Wires	Core Application & Compliance
SAE US Standard Low-Voltage Wire	GPT, TXL, GXL, SXL	General cabin wiring, thin-wall compact layout, high-temperature engine bay & chassis exposure; ISO 6722 Class A/B/C certified
European Automotive Standard Wire	FLRY	Lightweight thin-wall wiring for European passenger vehicles, low-smoke insulation for interior electronics
Japanese Automotive Standard Wire	AVSS	Ultra-thin wall lightweight harnesses for Japanese OEM passenger car body & dashboard systems

Automotive Wire Harness Expertise

Comprehensive Understanding of Vehicle Architectures

Our automotive engineering team evaluates and designs fully custom wire harness solutions from four core professional dimensions: application type, voltage standard, environmental durability and OEM engineering compliance. All wiring assemblies are tailored to your vehicle’s unique architecture, with full alignment to IATF 16949, ISO 6722 and global regional automotive regulations.

By Harness Type & Application

Power & Propulsion Harnesses

Engine bay wiring, transmission and auxiliary power harnesses for ICE passenger vehicles and heavy-duty commercial trucks. Designed for high continuous current, severe vibration and wide Underhood temperature range (-40°C to +125°C).

Safety & ADAS Networks

Shielded cable assemblies for airbag deployment, brake control systems and autonomous driving sensors (LiDAR/Radar). Manufactured for zero-fault performance and strict EMC interference compliance.

Body

Lighting circuits, door module assemblies and seat wiring harnesses optimized for flexible routing, compact layout, moisture resistance and chemical corrosion protection.

By Voltage Class & Standards

High-Voltage (>60V DC)

Limited custom high-voltage assemblies for small-volume EV auxiliary modules, using orange XLPE insulated cables and sealed HV connectors complying with IEC 61851 isolation rules.

Low-Voltage (12V/24V Systems)

12V architecture for traditional ICE passenger vehicles; 24V circuits for commercial trucks & off-road machinery. All wires adopt PVC/TXL/GXL insulation with copper conductors fully certified to ISO 6722 global automotive low-voltage standard.

Regulatory Compliance

All custom harnesses undergo full validation to meet IATF 16949, USCAR specs, ECE and FMVSS regional standards for seamless global market export.

By Environmental Challenges

Thermal Management

Heat-resistant silicone/XLPE insulation for high-temperature engine compartments; cold-flexible wiring materials for frigid operating climates. All products complete thermal cycling testing ranging from -40°C to +150°C per ISO 6722 thermal grade requirements.

Fluid & Chemical Resistance

Fully sealed IP67/IP69K connectors and oil-resistant cable jackets to resist brake fluid, coolant, road salt and chemical corrosion over a full 15-year vehicle service lifecycle.

Mechanical Durability

Vibration-tuned strain relief structures, abrasion-resistant outer sleeves and fixed routing clips to withstand long-term road shock and sustained engine vibration frequencies.

The Kaweei Engineering Advantage

APQP & PPAP Support

We support complete automotive OEM development cycles via standardized APQP planning, full PPAP document submission and pre-mass-production validation to satisfy strict OEM quality gate requirements.

DFMEA & Design Validation

Our engineers conduct early-stage DFMEA reviews to identify potential failure risks in advance, optimize harness routing layout and extend long-term operational reliability before prototype production.

Prototype to Mass SOP One-Stop Service

From small-batch prototype samples to stable high-volume mass manufacturing, Kaweei delivers end-to-end custom automotive wiring harness support throughout your entire vehicle development timeline.

Detailed test data, DFMEA&PFMEA case studies and APQP implementation guides are available within our resource articles for in-depth reference

Production Workflow & Assurance

Automotive Wire Harness Manufacturing Process

Design & DFM Review

Engineering review, BOM analysis, and automotive compliance check.

Material Preparation

Automotive-grade copper, XLPE/PUR insulation, and sealed connectors.

Wire Processing

Precision cutting, stripping, and crimping per IPC/WHMA-A-620 Class 3.

Sub-Assembly

Connector housing, sensor integration, and waterproofing installation.

Final Assembly

Form board lacing with ±5mm accuracy, routing, and protective conduits.

Validation & Verification

Crimp force validation, dimensional inspection and process verification.

100% Electrical Testing

Continuity, insulation resistance, Hi-Pot (2× rated voltage) checks.

Quality Assurance Infrastructure

Supporting our production workflow with in-house capabilities and documentation.

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Automotive Testing Lab

In-house salt spray, vibration, thermal cycling, and mechanical durability tests to LV112 specifications.

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Full Traceability System

Complete documentation from raw materials to finished harness. Material certifications, test reports, and FAI reports available.

IATF 16949 ISO 9001 UL Recognized RoHS Compliant

Frequently Asked Questions

Common Questions About Automotive Wire Harnesses

Yes. We design and manufacture custom automotive wire harnesses for passenger vehicles, commercial vehicles, electric vehicles (EVs), off-road equipment and specialty automotive applications. Every harness is engineered to meet your electrical, mechanical and environmental requirements.

Yes. We can provide a Certificate of Conformance (CoC) and maintain component traceability based on customer requirements. Material records and production documentation help ensure product consistency and supply chain transparency.

We are IATF 16949 certified and follow automotive quality processes including APQP and PPAP. Our manufacturing system is designed to meet the quality expectations of automotive OEMs and Tier 1 suppliers.

Yes. We provide PPAP documentation according to customer requirements, including dimensional reports, material certifications, IMDS data and product test reports to support project approval and production launch.

Yes. We manufacture custom automotive wire harnesses based on CAD drawings, BOMs, technical specifications or physical samples. Our engineering team reviews every project to ensure manufacturability, quality and cost efficiency.

Every automotive wire harness is tested before shipment. Depending on project requirements, we perform continuity testing, insulation resistance testing, Hi-Pot testing, terminal pull-force testing and functional verification to ensure product reliability.

Yes. We manufacture prototype automotive wire harnesses for design validation, vehicle integration and functional testing before mass production. Prototype support helps reduce development risks and accelerate project timelines.

Yes. We support OEM and Tier 1 automotive customers with engineering collaboration, prototype development, PPAP documentation, quality control and high-volume automotive wire harness manufacturing.

Partner with Kaweei

Your Trusted Automotive Wire Harness Manufacturer

With 15+ years of OEM experience and IATF 16949 certification, Kaweei delivers reliable, high-performance wire harness solutions for automotive applications worldwide. Our engineering team is ready to support your next project.

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IATF 16949 Certified

Automotive-specific quality system

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Body & Chassis Wiring Expertise

Durable low-voltage harness solutions

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Rapid Prototyping

3-7 business day turnaround

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100% Electrical Testing

Every harness tested before shipment

Start Your Automotive Project

Submit your requirements, including BOM lists or technical drawings. Our engineering team will respond within 24 hours.

sales@kaweei.com

+86-769-8399-1366

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100% Confidential | No Obligation | Engineering Support Included

Automotive Wire Harness Manufacturer | IATF 16949 Certified OEM Supplier

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