High-Current Termination
Hydraulic and pneumatic crimping presses deliver consistent, gas-tight terminations on conductors from 18 AWG to 4/0 AWG. Every crimp is verified against...
Cable Assembly
Custom Battery Cable Assembly
High-current battery cable assemblies engineered for electric vehicles, energy storage systems, and industrial power applications. From 12V starter cables to 1000V DC EV battery harnesses — built to carry the power your application demands.
DC Rated1000V
Current Capacity500A+
Quality RateHigh
Max AWG4/0
Application Context
Battery cable assemblies for every voltage class and application
From high-voltage EV power cables to precision BMS harnesses — we manufacture the full range of battery cable assemblies for every application and voltage class.
Our battery cable assemblies power critical systems across six major industries where reliable energy delivery and safety compliance are non-negotiable.
Manufacturing Capabilities
Battery cable manufacturing capabilities
Purpose-built manufacturing lines for high-current battery cable assemblies. From precision wire processing to automated testing — every step engineered for safety-critical reliability.
High-Voltage Safety Compliance
Orange HV-rated jacketing, double insulation, and interlock circuits per SAE J1742 and IEC 62196. Every high-voltage assembly receives 100% hi-pot and...
Thermal Management Integration
Heat-shrink boots, silicone sleeves, and thermal barriers rated to 200°C protect connections in under-hood and battery compartment environments where heat...
BMS Harness Engineering
Multi-conductor BMS harnesses with voltage sensing leads, thermistor circuits, and CAN bus communication wiring. Precise wire length matching for balanced...
Busbar & Flexible Connector Design
Laminated copper busbars and flexible connectors for high-current battery module interconnects. Nickel and tin plating for corrosion resistance in sealed...
EMI/RFI Shielding Solutions
Braided and foil shields maintain signal integrity on BMS sense lines while preventing electromagnetic interference from high-current power conductors in...
Custom Connector Integration
We integrate connectors from Amphenol, TE Connectivity, Anderson, Molex, and other major brands. HV interlocks, manual service disconnects, and IP-rated...
Automated Vision Inspection
Camera-based inspection systems verify terminal crimp height, insulation strip length, and wire routing. Defects are caught before final assembly, ensuring...
Salt Spray & Environmental Testing
In-house salt spray chambers (ASTM B117), thermal cycling ovens, and humidity cabinets validate long-term reliability in automotive, marine, and outdoor...
Engineering Challenges
Review risk before production
Voltage Class & Insulation
Battery cables fall into LV (0–60V), HV Class A (60–600V) or HV Class B (600–1500V) — each class drives different insulation, color coding and testing, so the voltage class is fixed before material selection.
Continuous-Current Conductor Sizing
Conductor gauge is sized to continuous current draw, not peak, with ambient-temperature derating applied — a cable rated for 100A at 25°C may carry far less inside a hot battery compartment.
Thermal Environment & Derating
Battery cables heat up under load; service loops absorb thermal expansion and insulation class is chosen for the real compartment temperature, so a mis-judged thermal environment does not become a field failure.
High-Voltage Safety & Disconnect
HV systems require orange HV-rated jacketing, double insulation, interlock circuits and a clearly marked manual service disconnect per SAE J1766 / UN ECE R100 — all verified by 100% hi-pot testing.
Technical Capabilities
Technical specifications
Voltage RatingUp to 1000V DC (HV Class B)
Current Rating10A to 500A+ continuous
Wire Gauge Range22 AWG to 4/0 AWG
Conductor MaterialTinned copper, bare copper, copper-clad aluminum
Insulation TypesPVC, XLPE, Silicone, TPE, ETFE
Temperature Rating-40°C to +200°C (insulation dependent)
Shielding OptionsBraid, foil, spiral, combination shields
Terminal PlatingTin, nickel, silver, gold flash
Crimp MethodHydraulic, pneumatic, ultrasonic welding
IP RatingIP65 / IP67 / IP68 (with sealed connectors)
Hi-Pot Test VoltageUp to 5000V DC
Cable Length Range50mm to 15m+ per assembly
HV Jacket ColorOrange per SAE J1742 (HV cables)
Flammability RatingUL 94 V-0 available
MarkingLaser, hot stamp, label, printed sleeve
Manufacturing Process
Battery cable manufacturing process
01Requirements Review & DFM Analysis
02Prototype Build & Validation
03Wire Processing & Terminal Crimping
04Assembly & Routing
05Electrical Testing & Hi-Pot
06Final Inspection & Packaging
Quality & Testing
Quality assurance & testing
Every battery cable assembly undergoes comprehensive testing to verify it meets your electrical, mechanical, and safety specifications before shipment.
Hi-Pot (Dielectric Withstand)Insulation ResistanceCrimp Pull-ForceCrimp Cross-Section AnalysisVoltage Drop / ResistanceThermal Cycling
Why WHP
Why choose custom battery cable assemblies?
Off-the-shelf battery cables rarely meet the exact voltage, current, length, and connector requirements of modern battery systems. Custom-engineered cables ensure safety, performance, and regulatory compliance from day one.
Precise Current Capacity
Every conductor gauge, strand count, and insulation thickness is calculated for your exact continuous and peak current requirements. No oversizing waste, no...
High-Voltage Safety Built In
Double insulation, orange HV jacketing, interlock circuits, and hi-pot tested connections meet SAE J1742 and IEC 62196 requirements for safe operation in...
Thermal Performance Engineered
Insulation materials selected for your operating temperature range. Silicone and XLPE cables rated to 150°C for under-hood and battery compartment...
Exact-Length Manufacturing
Custom-cut to your exact routing requirements. Eliminates excess cable bulk in tight battery enclosures and prevents loose cables from contacting hot...
Reduced System Integration Cost
Pre-terminated, pre-routed cable assemblies install in minutes instead of hours. Eliminate field crimping errors, reduce assembly labor, and compress your...
Scalable from Prototype to Volume
Same engineering standards from 25-piece prototypes to high-volume production runs. Seamless transition from validation builds to mass production without...
FAQ
Frequently Asked Questions
What voltage and current ratings can your battery cables handle?
Our battery cable assemblies cover the full spectrum from 12V automotive starting cables to 1000V DC high-voltage EV battery connections. Current ratings range from 10A for BMS sense harnesses to 500A+ for main power distribution cables. We select wire gauge, insulation type, and terminal plating based on your specific voltage class and continuous current requirements.
Do you manufacture battery cables for electric vehicles?
Yes, EV battery cable assemblies are a core capability. We produce HV battery-to-inverter cables, battery module interconnects, BMS harnesses, and DC fast-charge inlet cables for passenger EVs, commercial vehicles, and electric buses. Our manufacturing is IATF 16949 certified and follows SAE J1742 high-voltage cable requirements.
What certifications do your battery cables carry?
Our battery cables are manufactured under ISO 9001:2015 and IATF 16949 quality systems. We use UL-recognized wires (UL 62, UL 758) and connectors. High-voltage cables comply with SAE J1742 and IEC 62196 safety standards. All materials are RoHS 3 and REACH compliant. PPAP documentation is available for automotive OEM and Tier-1 customers.
Can you produce custom BMS (Battery Management System) harnesses?
Absolutely. We build complete BMS harnesses including voltage sense leads, thermistor circuits, current sensor wiring, and CAN/LIN bus communication cables. Our wire processing equipment ensures precise length matching for balanced cell monitoring. Shielding options include foil, braid, and combination shields for EMI protection.
What is the minimum order quantity for custom battery cables?
Our minimum order is 25 pieces for prototype runs, which includes first-article inspection and full electrical test data. Production orders start at 50 pieces. We also offer blanket purchase orders with scheduled monthly or quarterly releases, which is popular with ESS and industrial equipment manufacturers managing seasonal demand.
How do you ensure safety on high-voltage battery cable assemblies?
Every HV battery cable undergoes 100% hi-pot testing at 2500V DC for 60 seconds to verify insulation integrity. We use orange HV-rated jacketing per SAE J1742, double insulation on conductors, and integrate interlock circuits on HV connectors. Crimp connections are verified by pull-force testing and cross-section micro-analysis. Full test data is recorded per serial number for traceability.
OEM Program Entry
Request Your Battery Cable Quote
Share your battery cable assembly requirements — voltage class, current rating, connector types, cable lengths, operating temperature and certifications. Our engineering team will review manufacturability and return DFM feedback before manufacturing starts.
We will review
- 01Design Feasibility
- 02Component Availability
- 03Cost Drivers
- 04Validation Requirements
Related Capabilities
Related Services
At a Glance
Dual-certified, high-voltage battery cable manufacturing
Dual CertifiedISO 9001 & IATF
China · Philippines2 Factories
High-Voltage RatedUp to 1000V DC
Prototype Lead Time7–12 Days
Product Range
Battery cable types we manufacture
From high-voltage EV power cables to precision BMS harnesses — we manufacture the full range of battery cable assemblies for every application and voltage class.
High-Voltage Battery Cables (60V–1000V DC)
Wire Gauge6 AWG to 4/0 AWG
Temp Range-40°C to +150°C
Properties: XLPE/silicone insulation, EMI shielded, orange safety jacket
Best For: EV battery packs, HV distribution, inverter connections
Low-Voltage Battery Cables (12V–48V DC)
Wire Gauge18 AWG to 2/0 AWG
Temp Range-40°C to +125°C
Properties: PVC/XLPE insulation, flexible stranding, vibration resistant
Best For: Automotive starting, UPS systems, solar storage
Battery Management System (BMS) Harnesses
Wire Gauge22 AWG to 14 AWG
Temp Range-40°C to +105°C
Properties: Twisted-pair signal wires, shielded, low-voltage sensing
Best For: Cell monitoring, temperature sensing, balancing circuits
Busbar & Laminated Battery Cables
Wire GaugeCustom copper/aluminum busbars
Temp Range-40°C to +150°C
Properties: Solid or laminated conductors, nickel-plated terminals
Best For: Battery module interconnects, high-current distribution
Battery Pack Charging Cables
Wire Gauge10 AWG to 4/0 AWG
Temp Range-30°C to +90°C
Properties: Flexible stranded copper, rated for repeated plug cycles
Best For: EV charging infrastructure, forklift charging, ESS
Battery Jumper & Interconnect Cables
Wire Gauge16 AWG to 2 AWG
Temp Range-40°C to +105°C
Properties: Color-coded, quick-disconnect terminals, fused options
Best For: Battery banks, telecom backup, marine dual-battery
Manufacturing Infrastructure
Equipment and connector sourcing
Manufacturing Infrastructure
- Hydraulic crimping presses for 4/0 AWG and larger terminals
- Automated wire cutting and stripping (18 AWG to 4/0 AWG)
- Crimp force monitoring with real-time SPC data logging
- Custom jig boards for repeatable cable routing
- In-house hi-pot testing to 5000V DC
- Climate-controlled material storage for insulation integrity
Connector Partners
We integrate battery connectors from all major manufacturers:
- Anderson Power
- TE Connectivity
- Amphenol
- Molex
- Deutsch (TE)
- JAE Electronics
- Aptiv (Delphi)
- Yazaki
- Sumitomo
- Tyco/AMP
- Phoenix Contact
- Custom Terminals
Industries & Applications
Industries we power
Our battery cable assemblies power critical systems across six major industries where reliable energy delivery and safety compliance are non-negotiable.
Electric Vehicles (EV/HEV)
- HV battery pack to inverter/motor cables
- Battery module interconnect harnesses
- BMS cell monitoring and balancing wiring
- DC fast-charging inlet cable assemblies
Energy Storage Systems (ESS)
- Lithium-ion rack battery interconnects
- Residential and commercial ESS power cables
- Grid-scale battery farm wiring harnesses
- BMS communication and sensing harnesses
Solar & Renewable Energy
- Solar battery bank connection cables
- Hybrid inverter to battery cables
- Off-grid power system harnesses
- Charge controller wiring assemblies
UPS & Data Center Backup
- UPS battery string interconnect cables
- Data center backup power harnesses
- Battery monitoring system wiring
- Hot-swappable battery module cables
Industrial & Material Handling
- Forklift battery pack cable assemblies
- AGV/AMR battery charging harnesses
- Industrial robot battery cables
- Warehouse equipment power connections
Marine & Transportation
- Marine dual-battery system cables
- Electric boat propulsion harnesses
- Locomotive battery bank wiring
- Emergency vehicle power cables
Explore our industry-specific wire harness solutions:
Testing Procedures
How we verify every battery cable
Every battery cable assembly undergoes comprehensive testing to verify it meets your electrical, mechanical, and safety specifications before shipment.
| Test | Description | Standard |
| Hi-Pot (Dielectric Withstand) | High-voltage insulation integrity testing between conductors and between conductor and shield/chassis | 2500V DC for 60 seconds (HV cables), 1000V DC for LV |
| Insulation Resistance | Measures resistance of insulation material to detect degradation or contamination | >100 MΩ at 500V DC per IEC 60243 |
| Crimp Pull-Force | Tensile testing of crimped terminals to verify mechanical integrity of the connection | Per UL 486A-486B, force values by wire gauge |
| Crimp Cross-Section Analysis | Microscopic examination of crimp zone to verify conductor compaction and void-free termination | Per IPC/WHMA-A-620 Class III, documented per lot |
| Voltage Drop / Resistance | Measures DC resistance across the full cable assembly to verify current-carrying capacity | Per SAE J1128, max mΩ per meter by gauge |
| Thermal Cycling | Repeated exposure to temperature extremes to validate long-term connection reliability | -40°C to +125°C, 500 cycles per IEC 60068-2-14 |
Certifications
Quality standards & certifications
ISO 9001:2015
Quality management system certified for battery cable manufacturing, ensuring process consistency from incoming material inspection through final test and...
IATF 16949
Automotive quality standard required by OEMs and Tier-1 suppliers for EV battery cable assemblies. Covers APQP, PPAP, and statistical process control.
IPC/WHMA-A-620
Workmanship standard for cable and wire harness assemblies. Class III high-reliability acceptance criteria applied to all safety-critical battery connections.
UL Recognized Components
UL-recognized wires, terminals, and connectors with full traceability. UL 62 rated cables for power applications and UL 758 for appliance wiring.
SAE J1742 & IEC 62196
High-voltage safety standards for EV battery cables covering insulation requirements, connector interlocks, and orange jacket color coding.
RoHS & REACH Compliant
All materials certified RoHS 3 and REACH compliant. Lead-free solder and halogen-free insulation available for environmentally regulated markets.
Pricing & Lead Time
Battery cable production tiers
From prototype validation through high-volume manufacturing — choose the production tier that matches your project phase and volume requirements.
Prototype Battery Cables
Quantity1–50 pcs
Lead Time7–12 business days
- Engineering review and DFM feedback included
- First-article inspection report (FAIR)
- Material and terminal selection assistance
- Electrical test data per piece
- Ideal for design validation and fit checks
Low-Volume Production
Quantity50–5,000 pcs
Lead Time12–18 business days
- Production jig boards for repeatable routing
- SPC-monitored crimping parameters
- Lot traceability with material certificates
- PPAP documentation available
- Scheduled release programs supported
High-Volume Production
Quantity5,000–500,000+ pcs
Lead Time18–25 business days
- Automated wire processing and crimping lines
- Dedicated production cells with Kanban
- VMI and consignment inventory programs
- Annual contract volume pricing
- Multi-site production for supply chain resilience
Design Tips
Battery cable design tips
Follow these engineering guidelines to specify battery cable assemblies that are safe, cost-effective, and optimized for your application.
Specify Voltage Class Early
Battery cables fall into LV (0–60V), HV Class A (60–600V), or HV Class B (600–1500V). Each class has different insulation, color coding, and testing...
Size Conductors for Continuous Current
Calculate conductor gauge based on continuous current draw, not peak. Account for ambient temperature derating — a cable rated for 100A at 25°C may only...
Plan for Thermal Expansion
Battery cables heat up under load and expand. Allow service loops and flexible routing sections to absorb thermal expansion without stressing terminals or...
Use Appropriate Terminal Plating
Tin plating is standard and cost-effective. Nickel plating resists higher temperatures. Silver plating minimizes contact resistance for high-current...
Include Manual Service Disconnect (MSD)
For any HV battery system, include a clearly marked manual service disconnect per SAE J1766 and UN ECE R100. This is a safety requirement, not optional for...
Document Torque Specifications
Battery terminal bolted connections require specific torque values. Under-torqued connections create hot spots and fire risk. Include torque specs on...
Engineering Perspective
Built for the load they carry
“Battery cable assemblies are the arteries of every energy storage system. A single high-resistance connection or undersized conductor can cause thermal runaway in the worst case, or chronic performance degradation at minimum. We apply the same engineering rigor to a 48V forklift battery cable as we do to a 800V EV battery harness — because every application deserves cables built for the load they carry, not just the price point.”
— Hommer Zhao, Founder & Technical Director, WellPCB
“The biggest risk in battery cable design isn't choosing the wrong wire gauge — it's underestimating the thermal environment. I've seen customers specify 100A cables based on room temperature ratings, then discover the battery compartment runs at 60°C under sustained load. That 30% derating changes everything: wire gauge, insulation class, and terminal plating. Our DFM review catches these issues before they become field failures.”
— Hommer Zhao, Founder & Technical Director, WellPCB