Custom Spade Terminal Wire Harness Manufacturer

Yihetai is a professional custom Spade Terminal Wire Harness manufacturer in China. With more than 23 years of experience in custom wire harness and custom cable assembly production, we provide reliable wiring solutions for power distribution, signal transmission, grounding, switching and internal equipment connections across a wide range of industries. Our product catalog already includes Spade Terminal Wire Harness as part of our terminal wire harness offering, and our manufacturing system supports everything from wire processing and terminal crimping to assembly, testing and final inspection.

Based on customer drawings, samples, BOM lists or application requirements, we can customize wire gauge, cable length, terminal size, terminal style, insulation type, conductor material, color coding, labeling, bundling method, shielding and special processing. Whether you need a simple OEM wire harness with a single fork terminal lead or a more complex custom wiring solution integrated with connectors, sleeves, heat shrink tubing or overmolding, Yihetai can support both prototype and volume production. As a wire harness manufacturer and cable assembly supplier, we serve industrial equipment, home appliances, automotive electronics, renewable energy systems, medical devices, lighting products and many other sectors. If you are looking for a dependable wiring harness factory or cable assembly manufacturer for your next project, contact us for fast engineering support and quotation.

What Is a Spade Terminal Wire Harness?

A Spade terminal wire harness is a customized wire or cable assembly terminated with spade-style terminals, also called fork terminals in some applications. The open-ended terminal shape allows fast installation and removal under screw or stud connections without fully removing the fastener, which makes it popular in equipment assembly, maintenance and field service.

Compared with standard off-the-shelf lead wires, a custom Spade terminal wire harness is designed around the actual electrical load, mounting space, terminal size, insulation requirement and operating environment of the end product. It can be made as a simple single-ended lead wire, a double-ended terminal cable, or a multi-branch harness integrated with connectors, sleeves, labels or protective tubing. For buyers and engineers, this means better fit, faster installation, lower assembly error risk and more stable electrical performance.

Common Custom Spade Terminal Wire Harness Types We Manufacture

We manufacture a wide range of custom Spade Terminal Wire Harness solutions, including:

Male spade terminal wire harness for tab insertion and power output connections
Female spade terminal wire harness for quick-disconnect mating applications
Male to female spade jumper harness for internal device wiring
Spade to ring / fork terminal harness for mixed connection structures
Insulated spade terminal harness for safer handling and better short-circuit protection
Non-insulated spade terminal harness for compact assemblies and custom insulation treatment
Flag terminal or right-angle spade harness for tight installation spaces
Piggyback and multi-branch harnesses for control boxes and distribution circuits
Spade terminal wire leads with sleeves, labels or heat shrink for organized assembly
Female spade terminal harnesses (2.8mm, 4.8mm, 6.3mm widths) for push-on connections
Locking spade terminal assemblies to prevent vibration loosening
Piggyback spade configurations for daisy-chaining circuits

We can also combine spade terminals with other terminal types such as ring terminals, bullet terminals, or connectors for hybrid designs.

Key Features of Our Spade Terminal Wire Harness

Custom lengths and wire gauges from 22-10 AWG for flexible installations.
Compatible with TE, Molex, JST spade terminals and stud sizes M4-M6.
Custom wire lengths, terminal combinations and branch layouts for different equipment structures and installation requirements.
Available in male, female, flag, piggyback and insulated quick-disconnect terminal configurations.
Supports multiple wire gauges, conductor types and insulation materials for power or signal applications.
High-quality crimping and optional soldering processes ensure stable electrical contact and mechanical strength.
Optional heat shrink, sleeve, tape wrapping and overmolding for better protection and neat appearance.
Suitable for vibration, bending, heat and routine service environments in industrial and consumer equipment.
100% electrical testing before shipment for continuity, polarity and connection reliability.

Technical Specifications

Parameter	Typical Options
Product Name	Spade Terminal Wire Harness
Wire Gauge	26 AWG – 10 AWG, customizable
Cable Type	Single wire, multi-core cable, UL wire, PVC wire, XLPE wire, silicone wire, PTFE wire
Conductor	Bare copper, tinned copper, stranded copper, customized conductor structure
Terminal Type	Male spade, female spade, flag terminal, piggyback terminal, quick disconnect terminal
Common Terminal Sizes	2.8 mm, 4.8 mm, 6.3 mm, customized
Terminal Material	Brass, phosphor bronze, tin-plated copper alloy, customized
Insulation Type	Non-insulated, PVC insulated, nylon insulated, heat-shrink insulated
Length	50 mm – 5000 mm or custom
Color	Black, red, blue, white, yellow, green, custom color coding
Temperature Range	Typically -40°C to +105°C, higher on request depending on cable material
Voltage Rating	300V / 600V depending on wire specification
Optional Processes	Crimping, soldering, ultrasonic welding, tinning, twisting, bundling, labeling, overmolding
Testing	Continuity test, polarity test, crimp pull test, insulation resistance, high-voltage test, visual inspection
Packaging	Bulk packing, labeled bundles, tray packing, custom packaging

Applications

Our Spade terminal wire harness solutions are widely used in:

Industrial automation equipment
Control panels and PLC wiring systems
Power supplies and transformer internal wiring
Industrial machinery and motor connection systems
Switches, relays and terminal block interconnection
LED lighting equipment and driver wiring
Home appliances such as ovens, heaters, fans and kitchen equipment
Consumer electronic devices requiring internal quick connection leads
Automotive electronic sub-assemblies and auxiliary wiring
Battery-related connection assemblies and energy equipment
Renewable energy equipment such as photovoltaic and energy storage systems
Medical and special equipment requiring stable internal cable assembly layouts

Customization Options

At Yihetai, all Spade terminal wire harness products can be customized according to customer requirements.

Custom Item	Available Options	Notes
Wire Type	UL wire, PVC wire, XLPE wire, silicone wire, PTFE wire, multi-core cable	Selected according to temperature, flexibility and application
Conductor	Bare copper, tinned copper, stranded copper	Custom strand structure available
Wire Gauge	26 AWG – 10 AWG or custom	Based on current load and installation space
Length	Fully customized	Tolerance can be controlled according to drawing
Color	Standard or custom color coding	Helpful for assembly identification
Connector	Optional housings or mixed-end structures	Can combine terminal and connector in one harness
Terminal	Male/female spade, flag, piggyback, quick disconnect	2.8 mm / 4.8 mm / 6.3 mm and custom sizes
Jacket / Insulation Material	PVC, XLPE, silicone, PTFE, nylon sleeve, heat shrink	Selected by environment and compliance needs
Process	Crimping, soldering, ultrasonic welding, bundling, taping, labeling, overmolding	Built to suit assembly and durability requirements
Testing	Continuity, polarity, pull force, hipot, insulation resistance, visual check	Customized according to product standard
Marking / Packaging	Labels, barcodes, serial numbers, kit packing	Available for OEM production management

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

As a experienced wiring harness factory, Yihetai produces spade terminal wire harnesses with advanced automation and skilled craftsmanship. Our facility handles prototypes to high-volume runs, using precision crimping machines for consistent fork terminal quality. From wire stripping to final bundling, we integrate spade terminals seamlessly into custom cable assemblies.

From material selection to final assembly, all processes are completed in-house, ensuring better cost control, consistent quality, and faster delivery.

Typical lead time for prototypes is 5-7 days, and mass production can be completed within 3-4 weeks, depending on order quantity.

Quality Assurance & Control

Quality control runs through the complete manufacturing flow of every Spade terminal wire harness project, from incoming materials to final packaging. We use documented process control, inspection records and traceable production steps to reduce variation and ensure each harness matches customer specifications, drawings and electrical requirements. Yihetai operates under a documented quality management system and holds ISO 9001:2015, UL and IATF 16949 certifications. Our production and testing resources include wire harness testers, terminal interface analyzers, tensile testers, impedance and electrical performance testing equipment, helping us maintain reliable quality for both prototypes and repeat orders.

Inspection items may include:

Incoming material inspection for conductor purity and insulation.
Terminal crimp pull test exceeding 100N force.
Visual and continuity checks on 100% of assemblies.
High-voltage test up to 1500V AC.
Dimensional and fixture inspection for spade fork alignment.
Environmental simulation for temperature/vibration.
Every harness delivers guaranteed electrical integrity and consistent quality across batches.

Why Choose Yihetai

25+ years of wire harness and cable assembly experience across multiple industries and applications

Strong engineering team for custom design and connector matching based on drawings, samples and application needs

Flexible manufacturing for prototype to mass production, suitable for both OEM development and stable supply programs

In-house process control and testing capability for better consistency, traceability and quality assurance

Certified quality system with ISO 9001:2015, UL and IATF 16949 support

Responsive custom service from a reliable China wire harness manufacturer and cable assembly supplier focused on long-term cooperation

Frequently Asked Questions

Can you customize the Spade terminal wire harness based on our drawing or sample?

Yes. We can manufacture according to customer drawings, physical samples, BOM lists or technical requirements, and we can help review the design for manufacturability.

What spade terminal types and sizes can you produce?

We can produce male and female spade terminals, insulated and non-insulated types, flag terminals, piggyback terminals and other similar terminal styles in common sizes such as 2.8 mm, 4.8 mm and 6.3 mm.

Can you make one side with a spade terminal and the other side with a connector?

Yes. We can build mixed-end assemblies with spade terminals on one side and connectors, ring terminals, ferrules, tinned wire ends or other custom terminations on the other side.

Do you support low-volume orders and sample development?

Yes. We support prototype development, sample making and low-to-high volume production depending on the project stage and customer requirements.

What industries commonly use Spade Terminal Wire Harness assemblies?

These harnesses are commonly used in industrial controls, home appliances, HVAC systems, automotive electronics, LED systems, energy equipment, medical support devices and other electrical assemblies requiring quick terminal connection.

Looking for a reliable spade terminal wire harness manufacturer?

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