Low Volume Wire Harness Assembly
Precision wire harness assembly for prototypes, pilot runs, and low-volume production. No MOQ, lead times from 5 days, 100% electrical testing, and full traceability. Trusted by engineers in medical, aerospace, and industrial R&D.
Why Choose Our Low Volume Service?
Designed for Innovation
- MOQ of 1: Perfect for prototypes, validation, and bridge production
- Fast Turnaround: As fast as 5 business days from approved design
- No NRE Fees: No setup charges for small runs
- Design Support: Free DFM feedback to improve reliability
Quality & Traceability
- IPC/WHMA-A-620B Compliant: Industry-standard workmanship
- 100% Electrical Testing: Continuity, polarity, and hi-pot testing
- Crimp Validation: In-line crimp force monitoring (CFM) on critical terminations
- Full Traceability: Lot tracking for wires, connectors, and components
Technical Capabilities
Our skilled technicians use precision tools and follow controlled processes to ensure consistency and reliability, even at the lowest volumes.
- Wire Gauge Range: 30 AWG to 8 AWG (0.05 mm² to 8.4 mm²)
- Termination Methods: Crimping (hand & pneumatic), soldering (with heat shrink), insulation displacement (IDC), screw terminals
- Connectors: Circular (MIL-DTL-38999, DIN), rectangular (AMP, Molex, TE), D-sub, USB, RJ45, terminal blocks
- Shielding & Grounding: Foil, braid, and combination shields with proper drain wire termination
- Labeling: Heat shrink tubing, flag labels, wrap labels, and printed wire markers (per IPC-2610)
- Overmolding & Potting: Available for environmental protection (IP67+)
Testing & Validation
We ensure every harness meets your electrical and mechanical requirements before shipment.
- Continuity Testing: Verifies correct wire routing and termination
- Polarity & Cross-Connection Checks: Prevents miswiring
- Hi-Pot (Dielectric Withstand) Testing: Tests insulation integrity up to 1500V AC (per UL 44)
- Functional Testing: Simulated operational checks with load
- Visual Inspection: Per IPC/WHMA-A-620B Acceptability of Electronic Wire Harnesses
- Test Reports: Provided for every order, including test parameters and results
Ideal Applications
Our low volume service supports innovation across demanding industries:
- Medical devices (prototypes and clinical trial units)
- Aerospace and defense (avionics, test benches, UAVs)
- Industrial automation (machine control panels, sensors)
- Renewable energy (solar inverters, wind turbine controls)
- Automotive R&D (EV prototypes, ADAS systems)
- Test and measurement equipment
Foire Aux Questions (FAQ)
What is the minimum order quantity (MOQ) for your low volume wire harness service?
Our minimum order quantity is just 1 unit. We specialize in prototypes, engineering validation builds, and small series production starting from a single harness.
What are your typical lead times for low volume wire harness assembly?
Standard lead time is 5 to 7 business days for prototypes and orders under 50 units. For more complex harnesses requiring sourcing of specialized components, lead time may extend to 2-3 weeks. Rush services are available upon request.
What information do you need to quote a custom wire harness?
To provide an accurate quote, we require a wiring diagram or schematic, bill of materials (BOM), mechanical drawing or layout (if applicable), termination requirements (crimp, solder, insulation displacement), and desired test procedures. A physical sample is helpful but not required.
Do you perform electrical testing on low volume harnesses?
Yes, 100% of our wire harnesses undergo electrical continuity and hi-pot (dielectric withstand) testing. We use automated test fixtures for repeatable results and provide test reports. Custom test plans can be developed for complex harnesses.
Can you help with wire harness design and optimization?
Yes, our engineering team offers free design for manufacturability (DFM) review. We can suggest wire gauge optimizations, connector alternatives, strain relief improvements, and labeling enhancements to improve reliability and reduce cost.
Start Your Low Volume Project Today
Upload your design or speak with our harness experts to get a quote within 24 hours.
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