Automotive & EV
IATF 16949 certified prototypes for electric vehicle powertrains, ADAS sensors, battery management systems, and in-cabin control modules.
- EV battery interconnects
- Autonomous driving sensors
- Infotainment systems
- Engine control units
Cable Assembly
Prototype Wire Harness & Cable Assembly Services
Production-quality samples in 7-10 days. Validate your custom cable assembly design with professional prototypes before committing to full production — complex assemblies only (10+ conductors, specialized connectors), built in IATF 16949 certified facilities. No MOQ, from 1 unit, with a free DFM analysis on every order.
Sample Turnaround7-10D
From 1 UnitNo MOQ
First-Pass YieldHigh
Max Conductors240+
Application Context
What is prototype cable assembly
Prototype cable assembly is a specialized manufacturing service that produces small quantities (1-50 units) of custom cable assemblies for design validation, functional testing, and certification — before committing to full-scale production. Building production-quality samples first lets you verify mechanical fit, electrical performance, and connector compatibility, and catch design errors early, when a fix costs a fraction of a post-tooling change and before you invest $5,000-$50,000 in production tooling.
We focus exclusively on complex, high-value cable assemblies — 10 to 240 conductors, multiple connector types, custom routing, EMI/RFI shielding, and specialized materials. We do NOT manufacture simple commodity cables like HDMI or USB; our equipment and processes are optimized for assemblies where precision, quality, and engineering expertise matter. Every prototype quote includes a free Design for Manufacturing (DFM) analysis, and samples are built with the same processes and equipment as production so what you test is what you get at volume.
When a prototype is ready for production release, our wire harness testing service defines the continuity, hi-pot, insulation resistance, pull-force, and documentation plan for recurring lots.
Applications
Industries we prototype for
Professional prototyping for high-reliability applications in automotive, medical, industrial, and robotics sectors.
Medical Devices
ISO 13485 supply chain compliant samples for diagnostic imaging, surgical robotics, patient monitoring systems, and implantable device interconnects.
- Surgical robot cables
- CT/MRI scanner harnesses
- Patient monitors
- Defibrillator assemblies
Industrial Automation
Rugged prototypes for PLCs, servo motors, industrial robots, CNC machines, and factory automation equipment.
- PLC control panels
- Servo motor cables
- Encoder feedback systems
- Industrial HMI interfaces
Robotics & AGV
High-flex assemblies for collaborative robots (cobots), automated guided vehicles, warehouse automation, and mobile robotics platforms.
- Cobot tether cables
- AGV power/data cables
- Robotic arm assemblies
- Vision system interconnects
Engineering Challenges
Review risk before production
Design Validation Risk
Identify design flaws, connector-compatibility issues, and manufacturing challenges on a real sample before committing to production tooling — when a fix still costs a fraction of a post-tooling change.
Connector Lead Time & Sourcing
Specified connectors can carry long lead times. We flag approved alternates before sampling and source authentic parts from a worldwide distributor network with full traceability.
Manufacturability (DFM)
A free Design for Manufacturing review checks the drawing, BOM, wire sizing, and terminations for cost drivers and manufacturing risk before the first sample is built.
Production Transfer
Prototype records, processes, and test plan carry forward to FAI, PPAP, and production release so the validated sample matches the production part — no re-tooling or supplier change.
Technical Capabilities
Prototype technical capabilities
IATF 16949 and ISO 9001 manufacturing across a wide range of conductor counts, connector families, and environmental specifications, from single samples to pre-production lots.
Standard Lead Time7-10 Business Days
Express / Rush3-5 Business Days
Minimum Quantity1 Unit (No MOQ)
Conductor Count10 to 240+
Wire Gauge Range28-10 AWG
Assembly Length50mm to 50+ meters
Voltage RatingUp to 1000V
Temperature Range-40°C to +200°C
Manufacturing Process
Our transparent prototyping process
01Technical Consultation & Requirements
02Quotation & DFM Review
03Global Component Sourcing
04Prototype Assembly & First Article
05Quality Testing & Documentation
06Secure Packaging & Express Shipping
Quality & Testing
Comprehensive testing & quality assurance
Every sample undergoes rigorous electrical, mechanical, signal integrity, and environmental testing to ensure your design performs as specified. Every prototype is 100% inspected before shipment, with test reports and certificates of conformance included.
Continuity & ResistanceInsulation ResistanceHi-Pot (1000-3000V)Contact ResistanceFlex Life TestingVibration (ASTM D999)Signal IntegrityTemperature CyclingIP67/IP68 Immersion
Why WHP
Why partner with us for complex prototypes
We're not a commodity cable factory — we're your specialized partner for high-value, complex prototype wire harness manufacturing.
Complex Assemblies Only
We don't waste resources on commodity HDMI or USB cables. Our expertise is in complex, high-value custom assemblies with 10+ conductors, custom routing, shielding, and specialized materials.
Global Component Sourcing
Our worldwide connector procurement network (Molex, TE, Amphenol, JAE, Hirose) provides 15-30% cost savings and 3-7 days faster lead times versus single-source competitors.
Production-Quality Samples
We manufacture samples using the same IATF 16949 and ISO 9001 certified processes as our production runs, ensuring your prototypes accurately represent production parts.
Global Technical Support
Our global office provides local timezone technical support, consultation in English, and worldwide business hours availability — no language barriers or delays.
Scalable Prototype to Production
Seamless transition from prototype (1-50 units) to low-volume (500+) to mass production (10,000+) without changing suppliers, re-tooling, or re-qualifying.
Rapid 7-10 Day Delivery
Our streamlined process, pre-stocked connector inventory, and dedicated production line deliver samples roughly 60% faster than the traditional 3-4 week industry norm.
Testing standards we follow
Prototypes are manufactured under our ISO 9001:2015 and IATF 16949 certified quality systems and tested to internationally recognized standards for quality and reliability.
IPC-A-620Cable Assembly
ISO 16750Automotive
ASTM D999Vibration
ASTM B117Salt Spray
FAQ
Prototype wire harness FAQ
What is prototype cable assembly?
Prototype cable assembly is the manufacturing of small quantities (typically 1-50 units) of custom cable assemblies to validate your design before full-scale production. Prototypes let you test mechanical fit, electrical performance, connector compatibility, and manufacturing feasibility without the cost and time of production tooling and large MOQs.
What is your minimum order quantity?
We have NO minimum order quantity. Whether you need 1 sample or 50 pre-production units, we can accommodate your requirements. This flexibility allows you to order exactly what you need for testing without wasting budget on excess inventory.
How long does prototyping take?
Standard lead time is 7-10 business days from order confirmation to shipment. This includes component sourcing (2-3 days), assembly (3-5 days), testing (1-2 days), and packaging. Rush service is available for 3-5 day turnaround at a 30-40% premium. International shipping via DHL/FedEx takes an additional 2-5 days.
Do you provide design services?
No, we do not offer design engineering services. We specialize in manufacturing excellence, not design consulting. However, we provide comprehensive FREE Design for Manufacturing (DFM) analysis ($500 value) with every order. Our DFM review identifies potential manufacturing issues, suggests cost-reduction opportunities, and recommends alternative components if needed.
What types of cables do you NOT manufacture?
We do not manufacture simple commodity cables like standard HDMI cables, USB charging cables, or basic audio/video patch cords. Our expertise and equipment are optimized for complex, high-value custom assemblies with 10+ conductors, multiple connector types, custom routing, shielding, and specialized materials. If your project has fewer than 8 conductors and uses only standard connectors, we may not be the right fit.
Can you source connectors globally?
Yes! Global connector sourcing is one of our key competitive advantages. We have direct purchasing relationships with Molex, TE Connectivity, Amphenol, JAE Electronics, Hirose Electric, Phoenix Contact, and 100+ authorized distributors worldwide. This network allows us to offer 15-30% cost savings on connectors compared to single-source competitors, plus faster lead times (3-7 days reduction) thanks to multi-region inventory access.
Where are your manufacturing facilities located?
We operate 2 manufacturing facilities: China (primary facility for industrial and robotics) and Philippines (medical device assemblies with ISO 13485 ready supply chain). Our global office provides sales, technical support, and customer service worldwide but does not have manufacturing capabilities. This global footprint provides supply chain redundancy and geographic risk mitigation.
What testing is included?
Every sample undergoes 100% electrical continuity testing, insulation resistance verification, and visual inspection as standard. Additional testing available includes: Hi-Pot testing (1000-3000V), contact resistance measurement, connector insertion force, cable flex life, vibration resistance, temperature cycling, humidity exposure, salt spray corrosion, and IP rating validation. Test reports and certificates of conformance are provided with all shipments.
Can I transition prototypes to production with you?
Absolutely! We design our process to ensure seamless transition to production. Your samples are manufactured using the same equipment, processes, quality standards, and supply chain as production runs. When you're ready to scale from prototype (1-50 units) to low-volume (500+) or mass production (10,000+), there is no re-tooling, re-qualification, or supplier change required. This saves you weeks of time and thousands in transition costs.
What certifications do your facilities have?
Our facilities are ISO 9001:2015 certified for quality management systems and IATF 16949 certified for automotive manufacturing. Our supply chain is ISO 13485 ready for medical device applications. All assemblies are manufactured in RoHS and REACH compliant processes. We can provide material certificates, test reports, and certificates of conformance for every shipment.
How much do prototypes cost?
Pricing varies significantly based on complexity, connector types, wire specifications, and quantity. As a general guideline: Simple assemblies (10-20 conductors, standard connectors): $50-$150 per unit for 1-10 pieces. Complex assemblies (50+ conductors, military-spec connectors, overmolding): $200-$800+ per unit. Contact us with your specifications for a 12-hour quote review. DFM analysis and engineering support are always included FREE ($500 value).
OEM Program Entry
Ready to validate your wire harness design?
Submit your specifications and receive a 12-hour quote review with a free DFM analysis ($500 value). 7-10 day turnaround, no MOQ, high first-pass yield, and global technical support.
We will review
- 01Design Feasibility
- 02Component Availability
- 03Cost Drivers
- 04Validation Requirements
Related Capabilities
Related cable assembly services
Services that pair with prototype builds and take a validated design into production.
Transparent Pricing
Prototype pricing guidelines
Clear guidelines to help you budget. Final quotes receive a 12-hour engineering review based on your specific requirements, and every quote includes a free DFM analysis, 100% electrical testing, test reports, and secure packaging.
Simple Prototypes
$80-$200 per unit (1-10 pieces)
- 10-30 conductors
- Standard connectors (Molex, TE, Amphenol)
- Basic crimping and assembly
- Length up to 2 meters
Complex Prototypes
$250-$600 per unit (1-10 pieces)
- 30-120 conductors
- Multiple connector types
- Shielding or custom routing
- Length up to 10 meters
Advanced Prototypes
$700+ per unit (1-10 pieces)
- 120-240+ conductors
- Military-spec or custom connectors
- Overmolding or IP67/IP68 sealing
- Extreme specifications
Scope
Our limitations & what we don't manufacture
Transparency is key to a successful partnership. Here are the applications and specifications we cannot support, so you don't waste time on an incompatible inquiry.
We do NOT manufacture
- Simple Commodity Cables — Standard HDMI, USB, DisplayPort, Ethernet, audio cables, or any off-the-shelf consumer electronics cables.
- Low-Complexity Assemblies — Assemblies with fewer than 8 conductors using only standard connectors (below our complexity threshold).
- Direct-to-Consumer Products — We serve B2B customers only. No retail, e-commerce, or end-consumer sales.
- Fiber Optic Assemblies — We specialize in electrical copper assemblies only, not fiber optic or hybrid fiber-copper cables.
- Design Engineering Services — We provide manufacturing, not electrical design consulting or CAD drawing services.
Technical limitations
- Ultra-High Frequency (>12 GHz) — Our standard processes are optimized for signals up to 10GHz. Specialty RF/microwave assemblies require different expertise.
- Extreme Cryogenic (-100°C or lower) — Standard materials are rated -40°C to +200°C. Liquid nitrogen or extreme cryogenic applications are not supported.
- Nuclear / Radiation Hardened — Assemblies for nuclear power or high-radiation environments require specialized materials we don't stock.
- FDA Class III Medical Implantables — Our ISO 13485 ready supply chain supports external medical devices, not surgically implantable products requiring FDA Class III certification.
- Explosive / Hazardous Atmospheres (ATEX Zone 0) — We can support Zone 2 applications but not Zone 0/1 requiring intrinsically safe certification.
Guarantees
Quality guarantees & policies
Clear policies that protect your investment and ensure successful prototype outcomes.
Prototype-to-Production Guarantee
Your approved prototype is manufactured using identical materials, connectors, wire specifications, and processes when you transition to production — no component substitutions without your written approval.
- Same connector brands and part numbers
- Same wire manufacturer and specifications
- Same assembly processes and quality standards
Rework & Replacement Policy
If your prototype fails to meet agreed specifications due to our manufacturing error, we remake it at no charge within 5 business days.
- Free remake for our manufacturing defects
- Design change requests charged at 50% of original quote
- Express shipping included for replacement units
NDA & IP Protection
We sign mutual Non-Disclosure Agreements to protect your proprietary designs, connector selections, and technical specifications.
- Standard NDA template or your company agreement
- Segregated project files with access control
- No design reuse without written permission
Shipping & Customs Support
We handle all export documentation, customs paperwork, and compliance certificates for international shipments. You pay only actual shipping costs — no hidden fees.
- Commercial invoice, packing list, certificates provided
- Import duties/taxes are your responsibility (standard practice)
- DHL/FedEx with full tracking and insurance