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The latest automobile electrical systems need precision-engineered harness assemblies that meet very strict automotive industry standards. OurPCB’s manufacturing process blends top assembly techniques with strong quality control for applications that prioritize safety.
We provide automotive wire harness manufacturing tailored for your needs. Our wire harness services can handle traditional vehicles, classing cars, and everything in between – complete with full testing and quality assurance. Take advantage of our special 5-day prototype delivery.
Automotive wire harnesses are structured cable assemblies of wires, terminals, and connectors that distribute electric power and signals throughout vehicles. These power distribution systems connect over 100 electrical components in modern automobiles, serving as the vehicle’s central nervous system. Wire harness assemblies organize individual cables into secure bundles that withstand automotive environmental conditions.
Automotive wiring harnesses are made up of electrical wire wrapped in insulation materials. It also has protective outer covers designed to automotive standards. The harness design includes specific kinds of wire gauges and connector types. There are also routing configurations personalized to each vehicle use. The latest vehicles have multiple harness assemblies. These include engine harnesses, dashboard harnesses, and more. There are even high-voltage battery harnesses for electric vehicles.
The wire harness manufacturing process requires compliance with industry standards, including IATF 16949 for quality management and IPC assembly procedures. These standards ensure harnesses meet automotive OEM requirements for reliability, safety, and performance in demanding automotive environments.
Professional wire harness manufacturing provides comprehensive custom solutions that eliminate electrical integration challenges while ensuring regulatory compliance. Our IATF 16949-certified processes deliver superior quality and cost-effective production for automotive applications.
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OurPCB combines IATF 16949-certified processes with world-class manufacturing capabilities to deliver superior automotive harness solutions. Our experienced engineering team provides comprehensive services from rapid prototyping to scalable high-volume production with in-house expertise.
Our dual 10,000 m² PCB assembly houses in Shenzhen and Shijiazhuang are equipped with high-speed SMT assembly lines capable of placing fine-pitch parts with ±25 µm tolerance.
Each line includes temperature- and humidity-controlled environments, active anti-static systems, and vacuum transport for handling thin or flex printed circuits.
We are fully certified to ISO 9001, IATF 16949, and IPC-A-610 Class 2 & 3, supporting applications where fine-pitch PCB assembly must meet elevated acceptance criteria for solder joint geometry, lead coplanarity, and component body clearance.
Our QA workflows are built to handle fine-pitch PCBs requiring zero solder bridging and uniform joint fillets across dense arrays.
All assemblies involving ball pitch under 0.5 mm, QFN, or PoP packages undergo X-ray inspection, SPI, and AOI with 15 µm resolution optics.
We detect voids, open leads, insufficient solder, lifted terminations, and hidden shorts. This inspection process is a requirement for successful assembly when working with components that provide no visible solder access.
Every fine-pitch electronic assembly receives a DFM and DFA review focused on stencil coverage, aperture tuning, pcb design limitations, and routing near fine-pitch ICs.
We assist in verifying pad design, thermal pad exposure, and via escape planning, important for high I/O packages like BGA and chip scale layouts where misalignment or solder blockage can compromise yield.
We offer full assembly component sourcing through partners like Digi-Key, Mouser, and WPG, including traceable lots for hard-to-find or moisture-sensitive electronic components.
Components are stored under MSL-compliant conditions, with drying cabinets and vacuum packaging for all incoming fine-pitch parts.
OurPCB manufactures specialized automotive wiring harnesses designed for specific vehicle systems and applications. Our comprehensive product range covers all automotive electrical distribution requirements, from traditional powertrains to advanced electric vehicle systems. Each custom wire harness undergoes rigorous testing to meet automotive OEM specifications and environmental requirements.
Engine harnesses connect critical powertrain components including fuel injectors, ignition systems, sensors, and engine control modules. These cable and wire harness assemblies withstand extreme temperatures up to 200°C and resist automotive fluids including oil, coolant, and fuel exposure.
Dashboard harnesses integrate infotainment systems, climate control, instrument clusters, and safety systems including airbag controllers. These custom wire harnesses require precise routing and connector configurations for efficient vehicle assembly and serviceability.
Electric vehicle battery harnesses manage high-voltage power distribution from battery packs to motor controllers and charging systems. Specialized insulation materials and safety interlocks ensure safe operation at voltages up to 1000V DC with comprehensive fault protection.
OurPCB integrates PCB testing services directly into SMT, THT, and mixed-technology production lines.
AOI, ICT, and functional test platforms are embedded at key points across our two 10,000 m² facilities in Shenzhen and Shijiazhuang.
Boards pass through automated inspection and electrical test stages without manual handling, reducing contamination risk and improving test repeatability across Class II and III assemblies.
We build all ICT and functional test fixtures internally using CAD-based modeling, high-precision CNC drilling, and pogo-pin calibration systems.
Fixtures are validated for flatness, probe pressure uniformity, and node-to-net correlation before use.
This internal control allows us to shorten test development cycles for new PCB assembly testing services and maintain consistency across repeat orders or multi-site deployments.
Our test infrastructure includes high-speed AOI (25 µm resolution), 5 µm X-ray inspection, 4-wire flying probe testers, and digital high-voltage dielectric testers.
Resistance measurements down to 10 mΩ, voltage capture from 100 mV to 1500 VDC, and insulation resistance over 1000 MΩ ensure detailed diagnostics for every PCB testing service.
Measurement integrity is maintained through ISO-calibrated instruments and logged reference values.
We provide serialized test data with barcode traceability, linking each board to its BOM revision, test station ID, operator, and timestamp.
Reports include fail point coordinates, signal path diagnostics, image references (for AOI/AXI), and environmental test logs.
Our infrastructure supports full compliance with ISO 9001, IATF 16949, and medical-sector audit requirements, making our PCB functional testing services suitable for regulated deployments.
Our testing flows conform to IPC-A-610H Class III for high-reliability electronics, including burn-in testing, dielectric breakdown validation, and full visual and optical inspection of PCBs before final sign-off.
We support test plans that include ESS, startup sequence monitoring, and functional loop stress testing to simulate real-world deployment.
All solder joints, including BGA and QFN, are inspected using 3D AOI and void-mapped X-ray analysis.
Comprehensive quotes for PCB testing services and fixture-based setups are delivered within 48 working hours.
For new PCBA designs, we provide a DFT assessment, pin map verification, and component access review before test planning begins.
This early-stage input improves test coverage, minimizes false failures, and enables rapid onboarding for customers requiring PCB assembly testing services with complex or high-mix builds.
OurPCB conducts comprehensive testing procedures to validate automotive wire harness performance under real-world operating conditions. Our testing protocols exceed automotive industry standards and ensure reliable performance throughout vehicle service life. All testing procedures follow documented protocols with complete traceability and certification.
| Test Parameter | Specification | Standard |
|---|---|---|
| Continuity Testing | < 1-ohm resistance | IATF 16949 |
| Insulation Resistance | >100 MΩ @ 500V DC | Automotive OEM |
| High-Voltage Dielectric | 2x operating voltage + 1000V | UL Standards |
| Current Carrying Capacity | 125% rated current @ 25°C | Automotive Standards |
Environmental testing simulates automotive operating conditions including temperature extremes, vibration exposure, and humidity cycling. Our environmental chambers replicate real-world automotive environments to validate harness durability and performance with the shortest lead times.
OurPCB provides a comprehensive range of automotive wire harness manufacturing solutions designed to meet stringent automotive quality requirements. We deliver precision assembly, rigorous testing, and complete documentation packages for all automotive applications serving global customers.
We integrate Surface Mount Technology components within automotive wire harnesses for compact and high-performance automotive electronic systems. Utilizing state-of-the-art pick-and-place machines, we ensure precise placement of electrical and electronic components directly onto wire harness assemblies for advanced automotive applications.
We offer versatile automotive harness manufacturing options as a wire harness manufacturing company. You can supply your own components and specifications, or choose our turnkey service, which includes sourcing, harness assembly, and delivery of finished automotive wiring systems with complete documentation.
Our custom automotive harness manufacturing service is tailored to your specific vehicle designs and special requirements. We manage complex automotive layouts and work closely with you as car wire harness manufacturers to ensure all your automotive electrical system requirements are fully met with optimized routing and connector configurations.
We specialize in rapid and reliable automotive wire harness manufacturing as automotive wire harness suppliers. Our quick turn service provides the highest quality automotive harnesses within tight deadlines, all while maintaining strict IATF 16949 quality standards for automotive applications with complete testing and documentation.
We produce automotive wire harnesses that meet IPC Class 3 certification, which is critical for automotive safety and reliability applications. These harness assemblies guarantee the highest level of reliability for mission-critical automotive systems including airbag systems, brake controllers, and steering systems with aerospace-grade quality.
We handle the manufacturing of all automotive connector configurations with high precision as automotive wiring harness manufacturers, including waterproof connectors, high-current connectors, communication connectors, and safety system connectors. Our advanced machinery manages complex automotive connector packages including sealed connectors for harsh environments.
OurPCB’s manufacturing capabilities encompass complete automotive wire harness manufacturing from wire harness design consultation through final testing with automated wire processing machines, precision crimping equipment, and environmental testing chambers. Our automotive engineering capabilities include circuit analysis, electromagnetic compatibility assessment, and thermal management evaluation for CAN bus, LIN bus, and Ethernet communication protocols in modern vehicle systems.
Quality assurance capabilities include statistical process control, automated testing systems, and comprehensive documentation packages meeting automotive traceability requirements with detailed records of material certifications and assembly procedures.
Our manufacturing process utilizes automotive-grade copper conductors with specialized insulation materials rated for continuous operation at 200°C with resistance to chemicals, abrasion, and UV exposure per automotive environmental specifications serving harness business globally.
OurPCB’s IATF 16949 certified automotive wire harness manufacturing delivers the quality, reliability, and technical expertise your automotive projects demand as a leading harness manufacturer. Our comprehensive services from rapid prototyping to high-volume production ensure seamless support throughout your product development and manufacturing lifecycle.
Contact our automotive engineering team today to discuss your wire harness requirements and discover how our certified processes and technical capabilities can accelerate your automotive program’s success with quality products.
Class III testing protocols are applied to automotive electronics, implantable and diagnostic medical devices, aerospace controls, and industrial safety systems with narrow fault tolerances and redundant circuit design.
All PCB testing services in this class follow IPC-A-610H Class III inspection standards and leverage elevated inspection thresholds, including 100% AOI coverage, post-reflow X-ray validation, and ICT with 95% minimum fault coverage.
Functional tests include thermal cycling simulations, startup-sequence monitoring, and analog signal stability under full operating load. Solder joint evaluation includes BGA voiding analysis (below 25% max area) and coplanarity verification to ±50 μm on all perimeter components.
Assemblies are electrically validated using high-accuracy power supplies, 4-wire resistance probes, and embedded sensor simulation modules that replicate actual use conditions. Environmental stress screening (ESS), burn-in testing, and optional conformal coating evaluation are included in high-reliability testing packages to qualify boards for long-term deployment in regulated sectors.
Every PCB testing service performed by OurPCB is logged with time-stamped records, fixture IDs, and unique board serial numbers for traceability across production lots. We integrate barcode scanning and digital record systems to track individual assemblies through each testing process, from in-circuit verification to final functional testing.
Electrical and inspection data are output in structured formats, including CSV, XML, and proprietary report templates compatible with MES and ERP platforms. Logged values include measured voltages, pass/fail status, detected fault types, and operator annotations. AOI and X-ray inspection systems capture and archive image files linked to serial numbers, enabling post-process review and historical analysis.
Each test result is indexed to the board’s BOM revision, date code, and routing lot, allowing for full backward traceability during quality audits or field failure investigations. Our traceability infrastructure meets the documentation and retention requirements for ISO 9001, IATF 16949, and IPC Class III PCB assembly testing services, supporting consistent product quality and regulatory readiness.
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OurPCB supports engine management systems, electric vehicle powertrains, ADAS safety systems, infotainment networks, and charging infrastructure applications. Our custom-manufactured wire harnesses serve automotive OEMs including traditional powertrain manufacturers and electric vehicle producers requiring specialized high-voltage capabilities and automotive communication protocols.
Our IATF 16949-certified quality management system includes statistical process control, automated testing systems, and comprehensive documentation with material traceability. Every high-quality wire harness undergoes electrical continuity testing, insulation resistance validation, and environmental simulation testing before delivery with complete certification packages meeting WHMA standards.
OurPCB supports automotive production from single prototype units to monthly volumes exceeding 100,000 pieces with scalable manufacturing capabilities. Our production systems include flexible scheduling, just-in-time delivery coordination, and automotive-grade quality systems designed for OEM volume requirements with consistent quality performance and competitive lead times.
Request a quote and get a custom testing plan tailored to your design, BOM, and inspection needs. We provide PCB testing services with full traceability, calibrated measurement systems, and certified workflows for Class II and Class III assemblies.
Prototype cable assemblies are the very important place in between PCB design ideas and interconnects. OurPCB brings prototype assemblies with PCB solutions to your tables.
PCB thermal management prevents component overheating through strategic heat transfer techniques. Without proper thermal control, electronics are at risk of electronic failures through weakened solder
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