Custom Wire Harness & Cable Assembly Services for OEMs

Custom Wire Harness • Cable Assembly • Crimping & Terminal Processing • Testing • PCB & Box Build Integration

Leader Global Electronics provides custom wire harness and cable assembly services for U.S. and international OEM customers, from prototype and NPI through repeat production.

We support custom cable and wire harness requirements for new product builds, manufacturing transfer, pilot production, and repeat production.

Our manufacturing support includes wire processing, crimping, terminal and connector assembly, labeling, inspection, continuity testing, component sourcing, and integration with PCB assembly and box build programs.

Send us your cable drawing, BOM, connector part numbers, quantities, and test requirements for quotation.

Email: sales@leaderelec.com.tw

NDA available upon request.

Wire Harness & Cable Assembly Capabilities

Depending on the product and customer requirements, our manufacturing capabilities can include:

Wire Cutting & Stripping
Crimping & Terminal Assembly
Connector & Terminal Processing
Heat Shrink Application
Cable Identification & Labeling
Wire Harness Assembly
Cable Assembly
Battery Cable Assembly
Power Cable Assembly
Signal Cable Assembly
PCB-to-PCB Interconnects
PCB-to-Panel Wiring
Internal Equipment Wiring
Continuity Testing
Polarity Verification
Functional Verification
Prototype, NPI & Production Support

Cable and wire harness assemblies can also be integrated with PCB assembly, mechanical assembly, functional testing, and complete box build programs.

Request a Wire Harness & Cable Assembly Quote

Please provide a complete RFQ package for the requested cable or wire harness assembly:

Cable or harness drawings, including dimensions, length tolerances, and connector orientation.
BOM with manufacturer names, full manufacturer part numbers, and quantities per assembly.
Connector housing, terminal, seal, and accessory part numbers, where applicable.
Wire specifications, including gauge, conductor construction, insulation requirements, and wire colors.
Pin-to-pin wiring table identifying connector references and cavity numbers, including the viewing direction used for connector drawings.
Shielding and drain-wire termination requirements, where applicable.
Assembly instructions covering splices, sleeving, heat shrink, strain relief, and other special requirements.
Quantities to be quoted and target delivery schedule.
Expected annual volume, if available.
Material supply model and a list of customer-supplied materials.
Mandatory sourcing restrictions or designated suppliers, where applicable.
Applicable document revisions and assembly variants.
Required inspections and electrical tests, including acceptance criteria where specified.
Test fixtures: customer-supplied or to be quoted, if required.
Labeling and packaging requirements.
Reference samples or photos, where available, to supplement the manufacturing documents.

If test fixture development is required, please provide the test requirements for a separate quotation.

For manufacturing transfer projects, include available work instructions, approved component information, existing test procedures, and known production or quality issues.

For projects that also include PCB assembly or box build, identify the additional manufacturing scope and whether programming or functional testing is required. Firmware and software files are not required for the initial quotation.

We begin quotation preparation once the required quotation information is complete and the manufacturing scope is confirmed.

Send your complete RFQ package to sales@leaderelec.com.tw.

An NDA can be arranged before you submit confidential files.

Engineering Review Before Production

Before production, our engineering team reviews the approved customer drawings, specifications, BOM, wire lists, samples, and applicable manufacturing documentation.

Depending on the project, typical review items may include:

Connector & Terminal Part Numbers
Pin Assignment
Wire Specifications & Gauge
Cable Length
Cable Routing
Bend Radius
Mechanical Clearance
Connector Orientation
Strain Relief Requirements
Heat Shrink Requirements
Labeling Requirements
Test Requirements & Accessibility
Assembly Instructions
Approved Components
Documentation & Revision Status

If an issue or inconsistency is identified that may affect sourcing, assembly, testing, or product integration, it can be reviewed with the customer before production.

For prototype, NPI, pilot, engineering revision, or manufacturing transfer projects, manufacturing documentation is reviewed before materials are purchased and production is scheduled.

Connector & Component Sourcing

Wire harness and cable assembly projects may require sourcing and coordination of:

Connectors
Terminals
Connector Housings
Wire & Cable
Heat Shrink Materials
Sleeving
Labels
Fasteners & Supporting Hardware
Customer-Specified Components

Customer-specified connector brands, manufacturer part numbers, AVL, AML, and approved suppliers can be followed where required.

Connector availability, lead time, lifecycle status, MOQ / SPQ, and other sourcing constraints can be reviewed during material preparation.

Alternative components or materials require customer review and written approval before purchase or use.

Quality Control & Testing

Inspection and testing requirements are defined according to the cable design, customer specifications, and manufacturing requirements.

Depending on the project, verification may include:

Visual Inspection
Connector Orientation Verification
Pin-to-Pin Continuity Testing
Polarity Verification
Cable Length Verification
Label Verification
Crimp Quality Inspection
Pull Force Testing
Functional Testing
System-Level Verification

Customer-defined inspection criteria and test procedures can be incorporated where required.

For products involving PCB assembly or box build integration, cable verification can also be incorporated into functional testing and final product inspection.

Manufacturing Documentation & Revision Control

Production documentation may include:

Cable Drawings
Wire Lists
Connector Specifications
BOM
Pin Assignment Tables
Assembly Instructions
Work Instructions
Labeling Requirements
Inspection Criteria
Test Procedures
Packaging Requirements
Approved Samples
ECO / ECN Documentation

Production is controlled according to the approved project revision and customer-provided manufacturing documentation.

Changes affecting components, wiring, assembly, labeling, or testing are reviewed before implementation.

Prototype, NPI & Repeat Production

We support wire harness and cable assembly projects from prototype and NPI builds through pilot and repeat production.

For early builds, connector selection, cable length, routing, mechanical fit, labeling, assembly methods, test requirements, and manufacturing documentation can be reviewed before repeat production.

For established products, material planning and production scheduling can be coordinated according to order quantity, forecast requirements, component lead times, testing requirements, and delivery schedules.

Manufacturing transfer and secondary-source programs can also be reviewed using available drawings, samples, approved component information, work instructions, test procedures, and revision records.

PCB Assembly & Box Build Integration

For OEM products requiring more than standalone cable assembly, wire harnesses and cable assemblies can be coordinated with:

PCB Fabrication
Component Sourcing
SMT Assembly
Through-Hole Assembly
PCB Inspection
Firmware Programming
Functional Testing
Mechanical Assembly
Wire Harness Installation
Cable Routing & Retention
Box Build Assembly
Final Product Inspection
Labeling & Packaging

This allows PCB assemblies, cables, wire harnesses, mechanical components, programming, and testing requirements to be managed within the same manufacturing program when required.

Typical Applications

Our wire harness and cable assembly services can support OEM products including:

Industrial Electronics & Automation
Industrial Control Systems
Embedded & MCU-Based Products
Power Electronics
Battery Management Systems (BMS)
Battery-Powered Equipment
Test & Measurement Equipment
Medical & Monitoring Electronics
Communication & Networking Equipment
IoT & Connected Devices
Industrial Displays & HMI Systems
Box Build & System Integration Projects

Actual cable construction, wire specifications, connectors, materials, inspection, and testing requirements are manufactured according to customer documentation and project requirements.

Typical Manufacturing Workflow

Engineering Review → Material Preparation → Wire Processing → Crimping & Terminal Assembly → Connector Assembly → Harness / Cable Assembly → Inspection → Electrical Testing → Labeling → Final Inspection → Packaging

For integrated manufacturing programs, PCB assembly, cable installation, firmware programming, functional testing, and box build operations can be incorporated according to the product requirements.

Wire Harness & Cable Assembly FAQ

Can you manufacture custom wire harnesses and cable assemblies?

Yes. Wire harnesses and cable assemblies can be manufactured according to customer drawings, wire lists, BOMs, connector requirements, samples, and manufacturing specifications.

Can you manufacture cable assemblies based on existing samples?

Yes. We can review existing samples to assess the manufacturing requirements and identify missing information.

Samples may not fully identify wire specifications, terminal part numbers, internal connections, or acceptance requirements. Any necessary drawings, material specifications, and test requirements must be documented and approved before the relevant purchasing or production activities begin.

Can you use customer-specified connectors and terminals?

Yes. Customer-specified connector brands, terminals, housings, manufacturer part numbers, and approved components can be used according to project requirements.

Can you provide continuity testing and inspection?

Yes. Depending on the project, inspection can include visual inspection, connector orientation, pin-to-pin continuity, polarity, cable length, labeling, crimp quality, pull force, and customer-defined verification requirements.

Can wire harnesses be supplied together with PCB assembly and box build assembly?

Yes. Wire harnesses and cable assemblies can be manufactured, installed, and verified as part of PCB assembly, functional testing, box build assembly, and complete system integration programs.

Request a Wire Harness & Cable Assembly Quote

For custom wire harness and cable assembly projects, please send your complete manufacturing files and production requirements.

Email: sales@leaderelec.com.tw

NDA available upon request.

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