Assembled in Kingston, NY

Custom Wire Harness Assembly Services

Custom wire harness assembly for multi-branch, discrete-wire harnesses: every wire cut, crimped, routed, bundled and labeled to your pinout.

Build a single prototype harness or 1,000+ production units in the same shop, with no minimum order and an engineer reviewing each order before a wire is cut.

Lay out your harness in the configurator for an instant price, or upload a drawing, wire list or formboard and we'll quote it.

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Harness or Cable Assembly?

Call It Whatever Your Team Calls It

"Wire harness" and "cable assembly" get used for the same parts all the time, and there's no industry-wide line between them. This page is written for harness people: individual wires, branches, breakouts, sleeving and labels. If you mostly buy jacketed cable, coax or shielded leads, the custom cable assembly page is the better starting point. Same process, same Kingston shop.

Harness Anatomy

What Goes Into a Harness We Build

A harness is a set of individual wires organized into one part. These are the pieces you specify, and the pieces we build to.

Wire List & Pinout: The source of truth: which pin on which connector goes to which pin on the next, in what gauge and color. We build and test every harness against it.
Branches & Breakouts: Where a group of wires leaves the main trunk toward another connector. Give each breakout position from a datum on your drawing and we put it there.
Bundling: Cable ties, tape or lacing hold the trunk and branches together. Our wire harness bundling guide walks through the options and when each makes sense.
Sleeving & Heat-Shrink: Braided or split sleeving over the trunk for abrasion, and heat-shrink at breakouts and connector backs to finish each transition neatly.
Labels: Heat-shrink markers or tags carrying wire numbers, connector reference designators or your part number, so whoever installs the harness knows which end goes where.
Formboard Layout: A 1:1 layout that fixes branch lengths and breakout positions. If you have one, send it with your drawing. If you don't, our design service can produce one.

Example Harnesses

Harness Layouts We Quote

Illustrative layouts, not customer projects. What they share is a trunk, branches, and a wire list that says where every conductor lands.

Machine controller harness

A Molex Mini-Fit Jr at the controller feeds a trunk that breaks out to three motors and two limit switches. Braided sleeving on the trunk, heat-shrink at every breakout, each branch labeled with the device it serves.

Vehicle upfit harness

Deutsch DT connectors on GXL wire, split loom over the main run, and a fused power branch. Breakout positions come from a dimensioned drawing so the harness drops straight into the chassis.

Battery pack harness

An XT60 main power lead with JST balance leads broken out along the pack, silicone wire where the harness has to bend, and polarity labels at each connector.

Product-internal harness

JST PH and GH housings linking a main board to a display, buttons and a sensor, with every wire cut to fit the enclosure and bundled with ties so the lid closes cleanly.

When the harness changes between builds

Prototype harnesses rarely survive revision A. When a pin moves or a branch gets longer, send the updated wire list or drawing with a new revision letter and we quote and build to it. With no minimum order, a single harness for revision B is an ordinary order, and it gets the same engineer review as the first one.

Connectors & Wire

Connector Families and Wire We Build Harnesses With

A harness usually mixes several connector families, one per device it plugs into. These are the ones we see most; anything else is a part number away.

Harness Connectors

JST: XH, PH, EH and GH housings for board-level signal and sensor harnesses
Molex: Mini-Fit Jr and Micro-Fit 3.0 for power and signal inside an enclosure
Deutsch: DT and DTM sealed housings for vehicle and equipment harnesses
TE Connectivity / AMP: rectangular housings and terminals called out on your drawing
Anderson Powerpole, XT30 and XT60: battery and power branches that carry higher current
Anything else: give us the manufacturer part number for the housing and contacts and we source it for your build

Choosing between Deutsch series? See Deutsch DT vs. DTM.

Hookup Wire Families

UL1007: PVC hookup wire, the everyday choice for electronics harnesses
UL1061: thin-wall PVC for dense connectors and tight bundles
GXL: cross-linked automotive primary wire
Silicone: very flexible insulation for harnesses that move or flex
PTFE: high-temperature, chemical-resistant hookup wire
Your spec: another wire family by part number, in the gauges and colors on your wire list

Build Process

From Wire List to Finished Harness

Engineer review

An engineer checks your wire list, drawing and connector part numbers against each other before manufacturing, and asks when something doesn't add up. First orders usually get a question or two.

Cut and strip

Each wire is cut to the length on your wire list and stripped for the terminal it will receive.

Crimp and insert

Contacts are crimped onto each wire end and seated in the housings, pin by pin, per the pinout. Pull testing is available on request.

Route, bundle and sleeve

Wires are routed into the trunk and branches, then bundled, sleeved and labeled the way your drawing specifies.

Test every circuit

Every harness gets a 100% continuity and pinout test against the wire list before it ships.

No drawing yet? Our wire harness design service turns a schematic, pin list, sample or sketch into a harness drawing, a pinout and wiring table with BOM, and a 1:1 formboard. It is quoted per job, on its own or together with the build.

Workmanship: We generally align with IPC, with tweaks to keep cost and lead time down. Talk to us!

Quote Checklist

What We Need To Quote A Custom Harness

Connector family names are not enough. Send housing part numbers, pinout, lengths, wire, and quantity. A drawing or wire list covers most of this in one shot.

Quote checklist

What to Include for a Fast Quote

Connector part numbers (housing MPNs, not just JST or Molex)
Pinout or wire list
Finished lengths and the length datum
Wire gauge, family, and color
Quantity and any price breaks

Send Harness RFQ

Full RFQ checklist

Pricing & Lead Time

How Harness Pricing Works

Instant configurator price

Place connectors and wires in the configurator and the price updates as you go, volume pricing included. When it looks right, order it.

Build Online →

Engineer-quoted drawings

Upload a drawing or wire list for a harness the configurator can't express. Quotes come back within 24-72 hours, counted in business hours, and usually include setup fees, sometimes tooling or NRE.

Upload for Quote →

No minimum

Order one harness or 1,000+. Orders under $49 carry a small-order fee. Lead-time options start at 10 business days for the fastest build; standard and economy builds take longer and cost less.

Customer Fit

Who Orders Harnesses From Us

Harness Buyers We Suit

R&D teams iterating on a prototype harness between design revisions
Hardware companies building 20 to 100 units a month without a bulk commitment
Teams who want one supplier from the first harness to the thousandth

Where Another Supplier Fits Better

High-volume, low-cost harness programs
Programs with demanding certification requirements

Industries

Wire Harnesses by Industry

Agricultural Technology

Harnesses that tie sensors, controllers and actuators together on field equipment and irrigation systems.

Automotive & Marine

Deutsch-terminated harnesses for vehicle builds, boats and upfits, with sleeved trunks and labeled branches.

Industrial Automation

Machine and panel harnesses that fan out from a controller to motors, switches and I/O points.

Electronics & IoT

JST and Molex harnesses that connect boards, displays and batteries inside a product enclosure.

Drones & UAV

Power distribution and flight-controller harnesses with XT connectors and tight routing through the frame.

Biotech & Life Sciences

Internal harnesses for laboratory and research instruments, built to the wire list your team maintains.

Wire Harness FAQ

Common Questions About Custom Wire Harness Manufacturing

What information do you need to quote a custom wire harness?

Connector part numbers (housing MPNs, not just JST or Molex), a pinout or wire list, finished lengths with the datum they are measured from, wire gauge, family and color, and quantity. A PDF drawing plus a wire list covers most of it in one go.

Can you build harnesses with branches and breakouts?

Yes. A main trunk that splits toward several connectors is ordinary harness work. Dimension each breakout from a datum on your drawing and we place it there; if the drawing leaves one open, the engineer reviewing your order will ask.

How are harness branches bundled and protected?

With whatever your drawing calls out: cable ties, tape, braided or split sleeving over the trunk, and heat-shrink at breakouts and connector backs. If protection isn't specified, we raise it during engineer review rather than guess.

Can you label individual wires and branches?

Yes. We add heat-shrink markers or tags printed with wire numbers, connector reference designators or your part number, at the positions your drawing shows.

Do I need a formboard drawing to order a harness?

No. A wire list with lengths is enough for a simple harness. Multi-branch harnesses go faster with a dimensioned drawing. If you don't have one, our harness design service delivers a drawing, a pinout and wiring table with BOM, and a 1:1 formboard, quoted per job.

Can one harness carry both power and signal wires?

Yes. Mixed gauges in one harness are normal: heavier conductors for the power branch, finer ones for sensors and data. List each wire's gauge and color in the wire list, and call out any wires that should be twisted together or kept apart in the bundle.

Can I order a single prototype harness?

Yes. There is no minimum order quantity, so one harness is a normal order; orders under $49 carry a small-order fee. The same shop builds 1 to 1,000+ units, so the harness you prototype is built the same way when volumes grow.

What lead time should I plan for a wire harness?

Our fastest lead-time option is 10 business days; standard and economy options take longer and cost less. You see each option with its price in the configurator and on your quote. Connectors we have to source for you can add time, and the quote says when they do.

What does your wire harness warranty cover?

Manufacturing defects, for 90 days from shipment. If a harness we built has one, we repair it free.

Ready to Get Started?

Three Ways to Start Your Wire Harness

Lay It Out Online

Drag connectors onto the canvas, wire them pin to pin, set lengths, and see the price.