High-Voltage EV Battery Management Harness500,000 Units Delivered
How WellPCB partnered with a leading electric vehicle manufacturer to deliver mission-critical battery management harnesses with industry-leading quality and on-time delivery.
Client Background
Industry: Electric Vehicle Manufacturing
Client: Leading EV Manufacturer (Under NDA)
A Fortune 500 automotive company developing next-generation electric vehicles needed a reliable supplier for their high-voltage battery management system harnesses. The harnesses required IATF 16949 certification, exceptional quality standards, and the capacity to scale to 500,000+ units annually.
The Challenge
High Voltage
1000V DC battery management system
Extreme Temperature
Operating range -40°C to +150°C
High Volume
500,000 units annual production
Zero Defects
Automotive PPAP Level 3 required
Our Solution
Custom PTFE Insulation
Selected high-temperature PTFE insulation rated for -65°C to +200°C, exceeding the operating requirements with a significant safety margin.
Overmolded Connectors
Designed custom overmolded connector boots providing IP67 sealing and superior strain relief for vibration resistance.
100% Hi-Pot Testing
Implemented 3000V dielectric testing on every unit, ensuring complete insulation integrity for high-voltage safety.
The Results
Project Timeline
"WellPCB exceeded our expectations on every metric. Their engineering team identified cost-saving opportunities during DFM review, and their quality has been flawless through 500,000+ units. They're now our preferred supplier for all high-voltage wire harness projects."