HV Wiring Harness Manufacturer | Custom 300V–1500V Solutions

The production of a high-voltage wiring harness is a meticulous process that combines engineering expertise with precision manufacturing. At WEITAI, we have refined this process over two decades, integrating advanced automation and rigorous quality controls to deliver products that meet the highest international standards.
Our journey begins with the selection of premium materials. For HV applications, we use conductors made of tinned or bare copper, chosen for their excellent conductivity and corrosion resistance. Insulation materials range from Polyvinyl Chloride (PVC) for general-purpose use to cross-linked Polyethylene (XLPE) and Polytetrafluoroethylene (PTFE) for high-temperature and high-voltage environments. For instance, our EV battery harnesses often utilize XLPE for its ability to withstand voltages up to 1500V and temperatures from -40°C to 150°C.
The design phase is collaborative and customer-centric. Our 35 R&D engineers work closely with clients to understand their specific requirements, including current rating, temperature range, and mechanical constraints. Using advanced CAD software, we create 3D models and electrical schematics, allowing for virtual validation before physical prototyping. This accelerates the development cycle, enabling us to deliver samples within 72 hours for standard modifications.
Once the design is approved, we move to manufacturing. Our production floor is equipped with automatic wire stripping, crimping, and cutting machines, ensuring high repeatability and accuracy. For example, our servo-driven crimping machines apply precise force, monitored in real-time, to achieve optimal crimp quality with a deviation of less than 0.02mm. This is crucial for maintaining low contact resistance and high current-carrying capacity.
Quality control is embedded at every stage. Incoming materials undergo rigorous inspection, and in-process checks are performed every 2 hours. After assembly, each harness undergoes comprehensive electrical testing, including hi-pot testing at 5000V DC to verify insulation integrity, and continuity testing to ensure proper wiring. Our commitment to quality is reflected in our 98% first-pass yield and a customer-reported defect rate of only 0.5%.
We are certified to ISO9001 for quality management, ISO13485 for medical devices, IATF16949 for automotive, and UL for safety standards. These certifications are not just badges; they are a testament to our disciplined processes and dedication to excellence.
Our factory covers 12,000 square meters and houses 350+ employees, with a production capacity of over 5 million harnesses annually. This scale allows us to offer competitive pricing while maintaining fast turnaround times—typically 2-4 weeks for production orders, depending on complexity.
Furthermore, we provide one-stop services including design support, prototyping, testing, and logistics. Our Hong Kong subsidiary facilitates international trade, ensuring efficient shipping to clients worldwide. We have exported to 30+ countries, including Germany, the United States, Japan, and Australia.
Real-world data underscores our capability. For instance, we delivered 100,000 high-voltage harnesses to a major Chinese EV manufacturer, achieving a 99.7% on-time delivery rate over two years. In another case, we helped a robotics company reduce their harness cost by 20% through design optimization and material selection.
In conclusion, WEITAI’s high-voltage wiring harness production is built on a foundation of expertise, advanced technology, and unwavering quality. We understand the critical role these components play in your products, and we strive to exceed your expectations with every order.