Custom Wire Harness
Build-to-print assemblies manufactured to customer drawings, BOMs, wiring diagrams or samples.
OEM · BUILD-TO-PRINT MANUFACTURING
Custom Wire Harness & Cable Assembly Manufacturer
Build-to-print wire harnesses and cable assemblies for OEM applications. From prototypes and low-volume builds to mass production, XSD manufactures to your drawings, BOMs, wiring diagrams, specifications, or samples.
ISO 9001 & IATF 1694910,000 m² Factory5 Million Wires/MonthPrototype to Mass Production
Get a Wire Harness Quote
OUR CUSTOMERS
Trusted by customers across industries
✓ISO 9001
✓IATF 16949
▥10,000 m² Factory
↗5 Million Wires / Month
⚙OEM Custom Manufacturing
→Prototype → Production
WHAT WE MANUFACTURE
Custom Wire Harnesses & Cable Assemblies for OEM Applications
Automotive Wire Harness
Custom harnesses for vehicle electrical systems and approved OEM specifications.
Battery Cable Assembly
Battery interconnection assemblies manufactured to project-specific requirements.
Energy Storage Cable
Custom cable assemblies for solar power and energy storage applications.
Industrial Wire Harness
Harnesses for machines, controllers, sensors and automation systems.
Agricultural Wire Harness
Wiring assemblies for tractors, harvesters and outdoor equipment.
Medical Cable Assembly
Customized cable assemblies manufactured to project-specific requirements.
MANUFACTURING
Complete Wire Harness Manufacturing Capabilities
From wire preparation and crimping to overmolding, assembly and electrical testing, XSD manages critical wire harness manufacturing processes within one production system.
Wire Cutting & Stripping
Automatic wire preparation for controlled conductor length and stripping dimensions.
Terminal Crimping
Controlled crimping for reliable electrical and mechanical connections.
Wire Twisting
Twisted pair and customized wire processing for specific electrical applications.
Injection Molding & Overmolding
Molded strain relief, insulation and component protection.
Harness Assembly
Fixture-assisted assembly for simple and complex multi-branch wire harnesses.
Testing & Inspection
Continuity, withstand voltage, pull-force and other project-specific inspection.
INDUSTRIES SERVED
Wire Harness Solutions for Demanding OEM Applications
Industrial Equipment
Harnesses for machines, controllers, sensors and automation systems.
Agricultural Machinery
Durable wiring assemblies for tractors, harvesters and outdoor equipment.
Medical Equipment
Customized cable assemblies manufactured to project-specific requirements.
Electric Motorcycle & E-Bike
Custom wire harnesses for electric motorcycles and e-bikes.
Electronics & Instruments
Custom wire harnesses for electronic devices and instruments.
ENGINEERING / CUSTOMIZATION
From Your Drawing to a Production-Ready Wire Harness
We Can Work From:
- 2D drawings
- Wiring diagrams
- BOMs
- CAD files
- Existing physical samples
- Connector/terminal specifications
- Application requirements
We Can Customize:
- Wire gauge
- Wire material
- Cable length
- Connector
- Terminal
- Branch configuration
- Sleeve / conduit
- Heat shrink
- Labels
- Clips
- Overmolding
- Protective materials
QUALITY CONTROL
Wire Harness Quality Control from Incoming Material to Final Testing
Incoming Inspection
Materials and components are checked according to project requirements before entering production.
First Article Inspection
Initial assemblies are reviewed against approved specifications.
Crimp Inspection
Crimped terminals are checked for connection quality and mechanical integrity.
Pull-Force Testing
Wire-to-terminal connection strength is evaluated according to project requirements.
Dimensional Inspection
Wire lengths, stripping dimensions and configurations are checked.
Electrical / Continuity Testing
Circuits are checked for correct connections.
Final Inspection
Finished harnesses are inspected before shipment.
Available Testing Capabilities
Testing is selected according to project requirements and approved specifications.
- Continuity testing
- Hi-pot / withstand voltage
- Pull-force testing
- Aging testing
- Salt spray testing
- Flame testing
- RoHS-related testing
- Project-specific electrical tests
MANUFACTURING PROOF
Inside Our Wire Harness Manufacturing Facility
10,000 m²Manufacturing Facility
5MWires / Month
OEMPrototype to Volume Production
QUALITY SYSTEMS
Quality Systems & Certifications
Our quality management system supports controlled manufacturing, inspection, traceability and continuous improvement for OEM wire harness and cable assembly programs.
Product/component compliance is evaluated for applicable products and customer requirements; it is distinct from company quality management certification.
RFQ PROCESS
How to Start Your Custom Wire Harness Project
Send Your Requirements
Upload drawing, BOM, wiring diagram or sample information.
Engineering Review
We review wires, connectors, terminals, dimensions, application and production requirements.
Quotation & DFM Feedback
Receive quotation and technical clarification where required.
Prototype / First Article
Samples are manufactured and inspected against approved specifications.
Production
Move into pilot or mass production after approval.
CUSTOMER FEEDBACK
What Our Customers Say
We have been working with XSD Harness on several custom automotive wiring harness projects, and the quality has been consistently reliable. Their team follows our drawings carefully and pays close attention to connector selection, crimping, and electrical testing. Communication is straightforward, and any technical questions are addressed promptly. XSD has become a dependable manufacturing partner for our ongoing production needs.
We needed a supplier capable of manufacturing complex wiring harnesses for our industrial equipment, and XSD handled the project professionally. Their engineering team helped clarify several details in our wiring diagrams before production started. The samples matched our specifications, and the transition to batch production went smoothly. We particularly appreciate their flexibility when dealing with customized requirements.
XSD has supplied custom cable assemblies for our energy storage equipment, and we have been pleased with the overall experience. The connectors, cable lengths, and assembly quality have met our technical requirements. Their quality inspections give us confidence when placing repeat orders. Deliveries have been well coordinated, which helps us maintain our production schedule.
Finding a manufacturer that understands the requirements of agricultural machinery wiring can be challenging. XSD worked closely with our team to produce customized harnesses with the correct protective sleeves, connectors, and branch configurations. The finished assemblies have performed well in our equipment, even under demanding operating conditions. We appreciate their attention to detail and consistent product quality.
We initially contacted XSD for a small batch of custom cable assemblies and were impressed with their responsiveness. Their team understood our requirements quickly and delivered samples that required very little adjustment. As our order volumes increased, they continued to maintain consistent quality and clear communication. We now consider XSD a valuable partner for our OEM manufacturing projects.
PROJECT QUESTIONS
Frequently Asked Questions
What information do you need to quote a custom wire harness?
You can provide a 2D drawing, wiring diagram, BOM, 3D CAD file, technical specification, or physical sample. If some information is not yet available, send your initial design or requirements so our engineering team can advise what additional information is needed.
Can you manufacture from an existing sample?
Yes. XSD can manufacture custom wire harnesses based on physical samples, drawings, CAD files, wiring diagrams, BOMs or technical specifications. Our engineering team reviews the requirements and manufacturing process.
Can you source customer-specified connectors and terminals?
Wire types, connectors, terminals and other components can be selected according to the approved design. Send the required specifications and part numbers for project review.
Do you support prototype and low-volume production?
Yes. We support prototype and low-volume builds for qualified OEM projects, followed by pilot and volume production where required. Minimum quantities depend on wire, connector, tooling and manufacturing requirements.
What wire harness testing do you provide?
Depending on project requirements, we provide continuity, insulation and withstand voltage, pull-force, aging, salt spray, flame, and RoHS & REACH-related testing. Procedures are selected according to customer specifications.
Can you support automotive wire harness projects?
XSD manufactures custom harnesses for automotive and other OEM applications and operates under ISO 9001 and IATF 16949 quality management systems. Send your project requirements for review.
What is your typical quotation lead time?
Standard RFQs are typically reviewed within 1–3 business days. Complex harness programs may require additional engineering evaluation.
Can you manufacture complex multi-branch harnesses?
Branch configurations, wire lengths, connectors, terminals, labels and protective materials can be customized according to the approved design. Send your wiring diagram and BOM for engineering review.