Custom EV Wire Harness Cable Assembly Supplier in China – Custom Cable Assembly and Harnesses Manufacturer-Built to Fit Your Exact Specifications

Custom EV Wire Harness Manufacturer

Yihetai is a professional custom EV wire harness manufacturer in China, providing reliable wiring harness and cable assembly solutions for electric vehicles, new energy vehicles, battery systems, charging equipment and automotive electronic control systems. As an experienced wire harness manufacturer, custom cable assembly supplier and wiring harness factory, we manufacture EV wire harness products according to customer drawings, samples, BOM lists or application requirements.

An EV wire harness is designed to transmit power, signals and control commands between different electrical parts in an electric vehicle or EV-related equipment. Based on your project needs, Yihetai can customize wire gauge, cable length, connector type, terminal type, insulation material, shielding, protective sleeve, waterproof structure, overmolding, labeling and wire color. Our custom wiring solution is widely used in electric cars, electric motorcycles, electric scooters, battery packs, BMS systems, charging piles, EV control modules, lighting systems, sensors and new energy equipment.

With more than 25 years of wire processing and custom wire harness experience, Yihetai supports both prototype development and mass production. Whether you need an OEM wire harness for an EV platform, a battery sampling harness, a low-voltage signal harness or a custom cable assembly for charging equipment, our engineering and production teams can help you build a cost-effective and reliable solution. Send us your drawing, sample or specification, and we will provide fast technical evaluation and quotation support.

What Is an EV Wire Harness?

An EV wire harness is a customized wire or cable assembly used to connect electrical and electronic systems in electric vehicles and related new energy equipment. It organizes wires, connectors, terminals, sleeves, labels and protective components into a structured harness that transmits power, signals and data between battery packs, BMS units, motors, controllers, sensors, charging systems and vehicle control modules.

Compared with a standard cable, a custom EV wire harness is designed according to the exact electrical load, installation layout, environmental condition and assembly process of the customer’s equipment. It can reduce wiring errors, improve assembly efficiency, simplify maintenance and increase system reliability.

EV applications often require higher safety and quality control than general electronic wiring. The harness must support stable current transmission, reliable terminal crimping, correct circuit identification, insulation performance, vibration resistance, temperature resistance and long-term durability. For battery pack and charging applications, connector matching, cable protection and 100% electrical testing are especially important.

As a cable assembly manufacturer with automotive and new energy experience, Yihetai supports custom EV wire harness projects from prototype development to mass production.

Common Custom EV Wire Harness Types We Manufacture

Common Custom EV Wire Harness Types We Manufacture
Yihetai manufactures different EV wire harness and EV cable assembly products for electric vehicles, battery systems and charging-related equipment.

Common types include:

EV battery pack wire harness
BMS wire harness for battery management systems
Battery sampling harness for voltage and temperature signal collection
EV high voltage cable assembly
EV low voltage signal wire harness
Electric vehicle controller wire harness
Motor controller cable assembly
Charging port wire harness
EV power distribution wire harness
Battery module connection harness
Energy storage wire harness
Electric motorcycle wire harness
Electric scooter wiring harness
Electric forklift and industrial EV wire harness
Waterproof EV connector cable assembly
OEM wire harness for new energy vehicle electronic modules

We can manufacture simple two-wire cable assemblies, multi-branch harnesses, shielded signal cables, high-current power cables, overmolded cable assemblies and complex custom wiring solutions according to your design requirements.

Key Features of Our EV Wire Harness

Custom cable lengths, branch layouts and circuit structures according to EV installation space and drawings
Suitable for battery packs, BMS systems, controllers, charging modules and electric power systems
Available in low-voltage signal wires, high-current cables, shielded cables and multi-core cable assemblies
Compatible with TE, Molex, JST, Amphenol-style, Deutsch, Hirose and customer-specified EV connector systems
Optional corrugated tube, braided sleeve, heat shrink, shielding, waterproofing and overmolding protection
High-quality crimping, soldering, ultrasonic welding, bundling and assembly for stable electrical performance
Designed for vibration, temperature change, moisture, abrasion and demanding EV operating environments
100% electrical testing before shipment to verify continuity, wire sequence and insulation performance

Technical Specifications

Parameter	Available Options
Product Name	EV wire harness / electric vehicle wire harness / EV cable assembly
Wire Gauge	10 AWG to 24 AWG, customized according to current and application
Cable Type	HV single-core, shielded multi-core, twisted pair, high-voltage cable
Conductor	Bare copper, tinned copper, stranded copper or customized conductor
Insulation Material	PVC, XLPE, TPE, silicone, PE, PP, PTFE or customized material
Connector Type	JST, Molex, TE, Deutsch, Amphenol, Anderson, Yazaki or equivalent
Terminal Type	Crimp terminal, ring terminal, blade terminal, Faston terminal, pin terminal
Protection	Corrugated tube, braided sleeve, heat shrink tube, PVC tube, tape wrapping
Temperature Range	Commonly -40°C to +105°C; higher temperature options available
Voltage Rating	Low-voltage and selected high-voltage designs according to customer specs
Waterproof Option	Sealed connector, rubber plug, heat shrink, overmolding or IP-rated design
Process	Cutting, stripping, crimping, soldering, ultrasonic welding, overmolding, assembly
Testing	Continuity, wire sequence, insulation resistance, Hi-Pot, pull force test
Production Type	Prototype, small batch and mass production
Quality System	ISO 9001:2015, UL and IATF 16949 quality management support

Applications

Our EV wire harness solutions are widely used in industrial electric vehicle systems, consumer electric mobility products and special new energy equipment.

Electric vehicle battery pack wiring
Battery management system BMS harness
Battery sampling and temperature sensor harness
EV motor controller wire harness
Power distribution unit wire harness
On-board charger cable assembly
DC charging module wire harness
Energy storage system wiring harness
Photovoltaic and battery storage connection systems
Electric forklift and industrial vehicle wiring
Electric construction equipment wire harness
AGV and intelligent logistics vehicle wiring
Electric scooter wire harness
Electric motorcycle wiring harness
Electric bicycle battery connection harness
Golf cart electric wiring harness

Low-speed electric vehicle wire harness
EV lighting and dashboard wiring
Seat, door, switch and control module wiring
Charging port and battery connector cable assembly
Custom EV accessory cable assembly
Smart mobility device cable harness
High-voltage EV cable assembly
Waterproof EV connector harness
Battery test equipment cable assembly
EV prototype and R&D test harness
Motorsport electric vehicle wiring loom
Emergency electric vehicle electronic systems
Battery swapping equipment wire harness
Charging station control cable assembly
Custom wiring solution for renewable energy and mobile power systems

Customization Options

At Yihetai, all EMI Shielded Cable Assembly products can be customized according to customer requirements.

Custom Item	Available Options	Notes
Wire Type	HV single-core, shielded multi-core, twisted pair, high-voltage cable	Selected by power, signal or communication function
Conductor	Bare copper, tinned copper, stranded copper	Customized according to current and flexibility needs
Wire Gauge	8 AWG to 24 AWG or customized	Based on current load, voltage and installation space
Length	Fully customized	Suitable for short jumpers and complex multi-branch harnesses
Color	Black, red, orange, white, yellow, blue, green or customized	Orange commonly used for high-voltage EV cables
Connector	TE, Sumitomo HV/LV JST, Molex, Deutsch, Amphenol, Anderson or equivalent	Connector matching support available
Terminal	Ring, blade, Faston, pin, socket, crimp terminal	Pull force test available for crimping quality
Jacket Material	PVC, XLPE, TPE, silicone, PE, PP, PTFE	Selected by temperature, flexibility and environment
Protection	Corrugated tube, braided sleeve, heat shrink, tape, overmolding	Improves vibration, abrasion and moisture resistance
Process	Cutting, stripping, crimping, soldering, welding, injection molding, assembly	Depends on product structure and application
Labeling	Wire labels, heat-shrink labels, barcode labels	Supports installation and traceability
Testing	Continuity, wire sequence, Hi-Pot, insulation resistance, pull test	100% electrical testing before shipment

We can manufacture based on customer drawings, samples, BOM lists or application requirements.

Send us your drawing, sample or specification for a fast quotation

Manufacturing Capability

Yihetai is a professional custom cable assembly manufacturer and wiring harness factory with integrated production capability for wire processing, terminal crimping, soldering, welding, assembly, bundling, sleeving, testing and final inspection. Our production range covers automotive harnesses, new energy harnesses, energy storage harnesses, photovoltaic harnesses, machinery wire harnesses and other custom wiring solutions.

For EV wire harness projects, we can support engineering samples, prototype builds, pilot production and mass production. Our process includes incoming material inspection, wire cutting, stripping, terminal crimping, connector assembly, heat shrink processing, sleeve installation, branch bundling, labeling, electrical testing, final inspection and packaging.

From material selection to final assembly and testing, all production processes are carried out under strict quality control to ensure consistent product performance and delivery reliability. Typical lead time for prototypes is 5-7 days depending on material availability and product complexity, and mass production can usually be arranged within 3-4 weeks after sample approval and material confirmation.

Quality Assurance & Control

Full-process quality control at Yihetai uses documented IATF 16949 systems, with SPC monitoring from wire prep to packing. Automated vision and pull testers ensure zero escapes in EV-critical components. Certified to ISO 9001:2015, IATF 16949 (automotive), UL for HV cables, and AEC-Q100 for components.

Specific inspection items include:

Incoming inspection for HV insulation resistance
Crimp pull/height test (>200N for HV)
Visual, continuity, shorts verification
High-voltage hipot/isolation (5kV+)
Dimensional checks on fixtures
Salt spray, thermal cycling simulation
HV interlock loop continuity
Every harness is delivered with guaranteed electrical integrity and consistent quality across batches

Why Choose Yihetai

With over 25 years of experience, Yihetai specializes in custom wire harness and cable assembly solutions for automotive, new energy, industrial, medical, home appliance, and electronic applications

Yihetai’s engineering team supports EV wire harness customization, from drawing review and connector matching to sample development for reliable mass production

Yihetai has proven experience in EV and new energy applications, supporting EV wire harnesses, battery harnesses, energy storage harnesses, automotive harnesses, and charging-related cable assemblies

Yihetai offers flexible production for EV wire harness projects, supporting prototypes, engineering validation builds, small batches, and long-term mass production

Yihetai controls wire cutting, stripping, crimping, welding, injection molding, assembly, and testing in-house to ensure stable quality and reliable delivery

As a professional wire harness and cable assembly manufacturer in China, Yihetai helps customers reduce costs while ensuring consistent quality control

Frequently Asked Questions

Can Yihetai manufacture EV wire harnesses according to our drawing or sample?

Yes. Yihetai can manufacture custom EV wire harnesses based on your drawing, sample, BOM list, connector part number or application requirements. If your drawing is not complete, our engineering team can help confirm wire gauge, connector type, terminal structure, length tolerance, sleeve protection and testing requirements before sample production.

What information should I provide for an EV wire harness quotation?

To provide an accurate quotation, we recommend sending the harness drawing, wire gauge, cable length, connector model, terminal type, material requirement, voltage and current requirement, quantity, testing standard and application environment. If you only have a sample or photo, we can also review it and help convert the requirement into a manufacturable solution.

Can you make EV battery sampling harnesses or BMS wire harnesses?

Yes. Yihetai can manufacture EV battery sampling harnesses, BMS wire harnesses and related signal connection harnesses for battery packs and new energy systems. These products can be customized with different wire colors, connector types, labels, branch lengths, protective sleeves and testing requirements to support accurate assembly and stable signal transmission.

Do you support waterproof or high-temperature EV wire harness designs?

Yes. We can provide waterproof connectors, sealed terminals, heat-shrink tubing, corrugated tubes, braided sleeves, overmolding and high-temperature wire materials according to your working environment. For applications exposed to vibration, heat, moisture or abrasion, we can recommend suitable insulation material, protection method and connector structure.

How does Yihetai ensure the quality of EV wire harness products?

Yihetai controls quality from incoming materials to final shipment. Key inspection steps include wire and terminal verification, crimp pull force testing, connector position checking, wire sequence checking, visual inspection, continuity testing, high-voltage testing and dimensional inspection. Each harness is tested before delivery to ensure correct assembly and reliable electrical performance.

Need a custom EV wire harness for your application?

Send us your drawing, sample or technical requirements, and our team will provide a customized wire harness or cable assembly solution for your project.