Wire Harness & Cable Assembly
A full turnkey electronic assembly manufacturer for prototype to high volume cable Assembly.
An Experienced Cable Harness Assembly Company For Your Electronics Assembly
Wires are the lifelines of every electronic system, connecting various subsystems and ensuring seamless communication between components. In complex PCB Assembly (PCBA) processes, even a small wiring error can lead to performance issues — that’s why precise testing and quality control are essential at every stage.
At STHL, we specialize in custom wire harness and cable assembly solutions that bring clarity, efficiency, and reliability to your electronic assemblies. Our team ensures each wire harness is meticulously designed and assembled to meet your product’s specific electrical and mechanical requirements. With years of experience in PCB and electronic assembly manufacturing, STHL delivers integrated solutions that enhance product performance, simplify maintenance, and extend service life — helping your electronics perform flawlessly in any environment.
Why choose STHL PCBA for cable harness assembly?
PCBA Compatibility - We ensure PCB Assembly compatibility as well as box build compatibility alongside your cable harness assemblies. You can have the ability to check the products and their compatibility during the manufacturing phase FAQs itself.
High-Precision - Our custom cable solutions can be designed as per your desired size and shape to best fit your boards. From bench-top equipment to fully automated cable assembling, you can rely on our craftsmanship for acquiring that high precision and accurate fitting for your box build or PCBs.
Higher Returns - At competitive prices, we provide high-quality products for low or high-volume production runs. We handle everything in-house to keep prices low and ensure consistent quality, even for complex cable harnesses.
Specialized Cable Harness Services - Our expertise lies in the production of ribbon cable, coaxial, and electromechanical assemblies. To ensure accurate harnessing, we verify data and implement revision controls to ensure reliable and consistent results.
Cable Harness Assembly Services We Offer
Our Capabilities
STHL combines advanced equipment with experienced engineering and production teams to deliver wire harness and cable assembly solutions across the full lifecycle — from prototype to volume manufacturing.
We adhere to strict technical specifications and testing protocols, and our design-for-manufacture approach streamlines wiring layouts, reduces footprint, enhances electrical and mechanical safety, and simplifies servicing.
DESIGN & ENGINEERING
Custom wire harness design - translate electrical, mechanical and environmental requirements into detailed wire harness specifications. Create electrical schematics and CAD drawings. Generate BOM (bill of materials), assembly instructions and test procedures.
MANUFACTURING
Manufacture wire harnesses using automated and manual processes. Add components such as connectors, terminals, and protective coverings. Use high-quality materials for insulation, durability, and environmental resistance.
QUALITY ASSURANCE
Perform continuity, voltage, and load testing.
Adhere to standards like IPC/WHMA-A-620 to ensure wire harness quality.Build and test prototypes to ensure functionality and compliance. Environmental testing to ensure reliability in harsh conditions.
Components Of A Wire Harness
1
Wires and Cables
Conductors —typically copper or aluminum— that transmit electrical power or signals.
2
Insulation
A layer of material used to protect the wires and prevent shorts, moisture, and environmental damage.
3
Connectors
Interface devices that securely connect wires to other wires or components.
4
Protective Sheathing
Additional coverings such as plastic tubing, fabric wrap, or heat shrink to shield wires from abrasion, heat, and moisture.
5
Terminals
Points in the harness where wires connect to other components using metal end crimping or soldering.
6
Mounting Hardware
Clips, ties, or fasteners used to secure the wire harness in place.
What is your minimum order quantity for cable assembly?
We have no strict MOQ. Prototype runs from 10–50 pcs are accepted regularly, particularly for NPI (new product introduction) and engineering validation stages. Production pricing applies from 500 pcs.
How quickly can you deliver cable assembly samples?
If connector and wire materials are in stock, prototype delivery is 3–5 business days. If your project requires imported long-lead connectors, we request sample materials immediately to meet your engineering timeline without delaying your production quote.
Do your cable assemblies conform to IPC/WHMA-A-620?
Yes. All cable production, crimping, assembly, and inspection follows IPC/WHMA-A-620. Class II applies to standard commercial and industrial products. Class III applies to medical and automotive projects requiring the highest reliability and documentation standards.
What Hi-Pot testing voltage do you support?
DC 300V to 1500V, or AC 100V to 1000V, depending on your product specification. Insulation resistance is tested to 10MΩ–100MΩ threshold. All results are recorded per assembly and available for audit.
Can you source Molex, TE Connectivity, or JST connectors directly?
Yes. We have direct procurement channels for Molex, TE Connectivity (Tyco), JST, Hirose (HRS), and Amphenol, with original Certificate of Conformance provided for each lot. For cost-sensitive programs, we also offer verified domestic connector alternatives with comparative test data.
Can cable assembly be combined with PCBA in the same order?
Yes — this is a core capability at STHL. Your cable assembly, PCB assembly, and box build can be processed in the same facility under the same quality system, reducing coordination overhead, shipping events, and traceability gaps that typically occur when using separate vendors.
How long do you retain quality records?
Standard ISO 9001 projects: 2 years. Automotive projects under IATF 16949: 15 years (including post-vehicle-lifecycle service periods). Medical projects under ISO 13485: minimum 5–10 years, aligned with product service life.
Are you able to support automotive and medical cable assembly simultaneously?
Yes. Our IATF 16949 and ISO 13485 certifications are both active and maintained concurrently, which means a single facility can produce to either standard — or both — within the same production cycle under separate work orders and documentation streams.
Cable Harness Assembly Material Types
We have gained adequate expertise in the design and manufacturing of custom cable harness assemblies in a cost-effective manner; but high-performance cable projects. Our solutions include the prototyping, design, development, and management of custom cable assembly for both low volume/high mix to high volume/low mix production capacities. Following are the different material types of electrical cable:
1. PVC (Polyvinyl chloride)
PVC is a synthetic plastic material that is commonly used in wire harnesses due to its low cost, durability, and resistance to fire, chemicals, and UV radiation. It is also flexible and easy to work with, making it a popular choice for a variety of applications.
2. Vinyl
Vinyl is another synthetic plastic material that is like PVC in many ways. It is also relatively low cost and durable, and it is resistant to moisture, chemicals, and UV radiation. However, vinyl is not as flexible as PVC, which can make it more challenging to work in some cases.
3. Thermoplastic elastomer (TPE)
TPE is a rubber-like material that combines the properties of rubber and plastic. It is known for its flexibility, resilience, and resistance to temperature, chemicals, and UV radiation. TPE is also easy to process and can be used in a wide range of applications.
4. Polyurethane (PU)
PU is a synthetic material that is known for its high strength, toughness, and resistance to abrasion and impact. It is also flexible and resistant to chemicals and UV radiation. PU is often used in harsh environments where wire harnesses need to withstand extreme conditions.
5. Polyethylene (PE)
PE is a thermoplastic material that is known for its low cost, flexibility, and resistance to moisture, chemicals, and UV radiation. It is also lightweight and easy to process, making it a popular choice for a variety of wire harness applications. However, PE is not as strong as some other materials and may not be suitable for all applications.