Cable Assembly
We build high voltage cable assemblies for EV platforms, energy storage, charging equipment, rail systems, and industrial power electronics, with shielding, orange safety identification, and 100% electrical validation matched to your actual operating environment.
Application Context
High voltage cable failures usually come from the interfaces: poor shield termination, damaged insulation, incorrect connector clocking, insufficient strain relief, or assembly steps that do not scale cleanly from prototype to production. Our process is designed around those risks, so the finished cable behaves consistently in the field.
High-voltage programs typically need clearer review gates than general cable assemblies because connector systems, insulation margins, shielding, and test criteria all carry higher downstream risk. Buyers often frame the insulation and safety expectations around these assemblies with high-voltage cable basics and IEC standards context.
We also account for applicable safety and workmanship expectations during review. For general compliance background, buyers often reference UL safety guidance and ISO quality-system principles when aligning supplier qualification requirements.
Build Scope
Six control areas that determine whether a high-voltage cable performs safely and repeatably in the field.
Custom high voltage cable assemblies for 600V, 800V, 1000V, and 1500V systems, with insulation systems selected around your operating voltage, current load, and installation envelope.
Braided, foil, and hybrid shielding options reduce radiated noise and support cleaner power delivery around inverters, chargers, drives, and high-current switching systems.
We build with orange jacketing, clear circuit marking, and keyed connector systems for projects that require visible high-voltage identification and safer field service handling.
Material stacks are chosen for under-hood, charging, rail, and industrial environments where thermal cycling, abrasion, vibration, and fluid exposure drive early failures.
Large-gauge conductor processing includes calibrated strip lengths, crimp force control, pull-force checks, and sealing methods matched to connector family and cable size.
Each lot can be validated with continuity, polarity, insulation resistance, and hi-pot testing, plus application-specific checks for shield integrity, interlock circuits, and connector retention.
Engineering Challenges
Shield termination design is handled carefully because poor shield grounding can undermine both noise performance and connector reliability on high-current switching systems.
Voltage class, conductor sizing, creepage and clearance constraints, and service environment are reviewed before a build plan is released, so insulation margins match the operating voltage.
Incorrect connector clocking and insufficient strain relief are common HV failure points, so routing validation, connector clocking review, and fixation are checked on first articles.
Assembly steps that do not scale cleanly from prototype to production drive field failures, so termination, shield handling, and sealing run to controlled process parameters in volume.
Technical Capabilities
Final specification depends on conductor size, current loading, ambient temperature, routing path, connector family, and shield architecture. We review those tradeoffs before quoting production.
Manufacturing Process
Quality & Testing
Each lot can be validated with continuity, polarity, insulation resistance, and hi-pot testing, plus application-specific checks for shield integrity, interlock circuits, and connector retention — with pull-force and visual inspection recorded for traceability before shipment.
Why WHP
High-voltage cable failures cluster at the interfaces. A dedicated build flow controls shielding, termination, and test criteria that generic cable RFQs miss.
High-voltage programs get clearer review gates than general cable assemblies because connector systems, insulation margins, shielding, and test criteria all carry higher downstream risk.
Braided, foil, and hybrid shielding with 360-degree shield termination reduces radiated noise and supports cleaner power delivery around inverters, chargers, drives, and switching systems.
Large-gauge processing with calibrated strip lengths, crimp force control, pull-force checks, and crimp height verification keeps 8 AWG to 4/0 AWG terminations consistent in production.
Continuity, polarity, insulation resistance, and hi-pot testing on every lot, with shield-integrity, interlock, and connector-retention checks where the application calls for it.
High-voltage assemblies are built to IPC/WHMA-A-620 workmanship with customer-specific inspection criteria under our ISO 9001 quality system.
FAQ
OEM Program Entry
Include your voltage class, conductor size, mating connector information, shielding requirement, cable length, routing environment, and annual demand. Drawings, sample photos, or an existing BOM help speed up review.
Related Capabilities
If your RFQ includes battery packs, environmental sealing, or complete vehicle harness scope, these pages help you choose the right production path before quoting.
Applications
Used where voltage, current, and service conditions make ordinary power cables fail early.
Battery disconnects, inverter feeds, charger harnesses, HVAC compressor power cables, and HV jumper assemblies for 400V and 800V vehicle platforms.
Cabinet-to-cabinet and module-to-busbar cable assemblies for stationary battery systems where current capacity, insulation coordination, and serviceability are critical.
High-current power leads and internal charger interconnects built for repeated thermal cycling, outdoor exposure, and connector sealing requirements.
High-voltage cable assemblies for traction, auxiliary power, and onboard conversion systems that need ruggedized jacketing, shielding, and long-term vibration resistance.
Custom power cables for servo drives, inverter cabinets, motor controls, and power distribution equipment where routing, bend radius, and EMC control matter.
Prototype and production assemblies for high-voltage test benches, power conversion equipment, and engineering rigs that require quick iteration and documented inspection.
RFQ
Send the cable details that let engineering review manufacturability and return DFM feedback quickly.