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Custom Wire Harness Materials
Normally, many customers already have wire harness designs, but some customers initially only have an idea. This is when they need us the most, because they are unclear about the selection of connectors and cables. These types of customers don’t have specific requirements for the appearance of the connectors. This is when QL-Custom truly takes control of custom wire harness applications and adds value. We are happy to help customers solve these types of problems.
Hook up wires and CAN signal wires options
Special Purpose Wire and Cables
Cable Fire Proof
UV Resistant Cable and Wires
Equal Wire and Connectors
Popular Brand Wire and Connectors
Rectangle or Circular Connectors
Custom Wire Harness Solution Service
Simply put, custom wire harness solutions meet all your wiring harness needs. Some suppliers don’t provide certain services, leaving customers to provide those. If everything is provided by the customer, what do we do? If we can't meet the customer's wire needs, what value do we add? How long can a supplier that doesn’t consider custom requirements survive? Therefore, you can rest assured when handing over your requirements to us. Your project is our project.
Twisted Wire Harness
Twisted wires help improve signal shielding, but some suppliers don't handle the twisting pitch correctly. For example, some customers request 2 turns per inch of twisting, but the supplier only gives 1.5 turns. This is often because they don't have enough wire length, cutting corners to save material.
Wire Harness Splices
There are three types of wire splicing: the most traditional is soldering and using wire terminals. We use ultrasonic welding, which completely eliminates issues like tensile force and current overload.
Wire Harness Cover Protector
Braided sleeving and convoluted tubing protection are the most common ways to protect wire harnesses. If you just need neatness, a tie wrap will suffice. But if it's for agricultural vehicle wiring, Yarn Braiding becomes the preferred choice.
Wire Harness Testing
Many wire harness suppliers still perform 100% continuity testing, but we also add a pin position test to ensure that terminals are in the correct position. Additionally, for automotive wire harnesses, we also conduct air-tightness testing.
Wire Harness Crimping Terminals Pull Force
Have you encountered a situation where large wires are crimped with small terminals? Our wire harness manufacturing experience often shines in these details. We have our methods to solve these problems.
Restricted Space Applications
What happens when our customers need to use wire harnesses in tight spaces? The choice of connectors is crucial. Micro and miniature connectors play a key role here. For example, for DB9 connectors, our recommendations are different.
Signal and Power Integration
Have you ever encountered a project that needed to integrate signal and power wires? We can provide solutions to meet these requirements by selecting the right wire and cable.
Wire Connector Mating Cycles Solutions
Have you ever had customers complain that the connector’s mating cycles didn’t meet the standard and loosened easily? We are capable of providing custom connector solutions to meet every plug/unplug force and durability requirement.
PCB Terminals for Soldering
We help customers choose the right PCB terminals that are suitable for soldering. The choice of terminal depends on the PCB hole diameter, and using hook terminals inserted into PCB holes helps prevent them from falling out, securing them during the soldering process.
Installable Wire Harness
Do you hate dealing with your current supplier who struggles with custom harnesses when trying to source different parts, including plastic and metal components? For them, it may be a challenge, but for us, mastering the production and procurement resources for these components makes the process simple. While we don’t directly manufacture, we are familiar with molding materials and mechanical processing, and we understand the quality inspection standards for these materials.
Custom Coiled Cable Solution
Have you ever encountered performance issues due to wrong material selection when you needed a coiled cable? The right wire material and filling are crucial. Let us help you with this.
Custom Wire Harness Shielding Solution
Has your custom wire harness project ever had issues with signal interference? This is often caused by poor shielding of the harness. We analyze everything from wire design to the distance between the wire and connectors, providing shielding solutions such as magnetic rings, braided wire shields, and outer casing shielding. By considering these elements early, we can help save time on prototypes and reduce production costs.
Custom Overmolded Cable Assemblies
When obtaining overmolded cable assembly quotes, have you often received mold quotes costing hundreds or even thousands of dollars? This is because the product hasn’t been made before. At QL-Custom, we have thousands of molds, which allows us to save costs wherever possible. Of course, if your requirements are special, we can also provide quotes in the shortest time.
Custom Tooling Service
From simple to complex molds, from PVC, TPE to high-temperature plastics, you can contact us to get the best and fastest quotes and solutions. We assist you in completing your project evaluation and implementation.
Special Purpose Plastic Overmolded Cables
When you have special requirements using TPE, TPU, or Nylon molding, you will notice that their molding temperatures and adhesion between the molded body and material are different. QL-Custom has fully mastered these molding techniques, including the temperature of the molding machines and the injection pressure adjustments.
Overmolded Hood Durability
When designing plug fixed positions, some customers may opt for panel mount requirements. Panel mounting needs to ensure whether the screws are external or internal locking, and determine the screw hole spacing and connector exposed length to avoid narrow terminal contact surfaces, which could increase current or signal impedance.
Panel Mounted Overmolded Cable Plugs
When designing plug fixed positions, some customers may opt for panel mount requirements. Panel mounting needs to ensure whether the screws are external or internal locking, and determine the screw hole spacing and connector exposed length to avoid narrow terminal contact surfaces, which could increase current or signal impedance.
Overall Cable Part Overmolding Solutions
Full encapsulation of the wires means that all wires between connectors are fully overmolded. Based on molding principles, the longest molding length can be 130-140mm, and anything longer could result in poor molding. This solution is suitable for short-distance FPC flat wires, as well as medical or adult product designs.
IP Rated Waterproof Overmolded Cable Harness Solutions
Custom cable harnesses with waterproof ratings require a concept of waterproofing in the overall product design. IP67, IP68, or even IP69 designs must use male and female connectors together, not just male connectors or female connectors. Or connectors to boards. The design must ensure a waterproof seal between solid hardware components when the male and female connectors are inserted or when connectors are mounted on boards. If just two pieces of hardware connect directly, complete waterproofing cannot be achieved.
Trust us one time , you will get more confidence to gain your expected product !
We are alway here to help your wire harness business
Custom Wire Harness Quotation and MFG Service
Are you still struggling to find the right custom wire harness supplier? Contact us to solve the difficulties you face and get a great quote. Contacting us will help you solve a series of challenges and ensure that your project will no longer struggle with custom wire harnesses. A quick and easy solution.
North America or Europe Customers
Do you think your local suppliers produce everything locally? If so, why do we have over a thousand customers in our industry? Contact us and you'll realize how affordable QL-Custom custom wire harnesses are, how reasonable our solutions are, and how fast our samples can be.
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Get a Very Quick Response Quote
From simple to complex wire harnesses, we only need 30 minutes to 4 hours to respond.
2
Quick Turn Samples
As long as the raw materials don't require customization, your sample can be shipped on the same day from the drawing to the first sample.
3
Mass Production
To ensure product quality, we usually complete production within 2-3 weeks based on quantity, but for larger quantities, we can discuss and determine the timeline together.
4
Guaranteed Quality
Every wire harness shipped from QL-Custom goes through 100% quality inspection, including both appearance and electrical performance. We always include a test report in the box with each shipment. Please check carefully upon receipt. If there is any quality feedback, we will immediately initiate an investigation. Therefore, when we ask you to sign the drawings, please make sure to confirm everything before signing and sending them to us.
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Custom Wire Harness Applications
Wire harness applications are very broad. If you want to know which industries wire harnesses serve, you can refer to the list we have provided, but of course, we serve beyond that. If you have additional questions or need to learn more, we are more than happy to assist. If you have cooperation needs, feel free to contact us. We will respond as quickly as possible.
Automotive
Electronics
Industrial
Medical
Mil
Outdoor
Robots
Sports
Aircrafts
Appliance
Agri Service
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