We build theharness yourdrawing specifies.
Custom wire harness and cable assembly manufacturer in India — terminated to your connector, built to your length, tested before it leaves. Low volume and high mix welcome, including the runs larger assemblers decline to quote.
we terminate to
sourced direct
before dispatch
Wire harness and cable assembly types we build
One part number, delivered built and tested — instead of a kit of loose parts your line has to terminate. In depth: wire harness manufacturing and cable assembly manufacturing.
- WH
Wire harnesses
Multi-branch looms with breakouts, taped or sleeved, routed and dressed to your drawing with connector callouts at every termination.
- CA
Cable assemblies
Point-to-point and multi-drop assemblies in single, multicore, shielded or twisted-pair construction, cut to length and terminated both ends.
- FRC
Ribbon & IDC assemblies
Flat ribbon cable with insulation-displacement terminations — daisy-chained, keyed and polarised, in the pitch your board is laid out for.
- RF
RF & coaxial assemblies
Coaxial jumpers and antenna leads with SMA, SMB, MCX, MMCX, BNC, FAKRA and U.FL terminations for radio, telematics and instrumentation.
- PWR
Power & battery leads
Heavier-gauge leads with ring, fork, bullet and blade terminations, insulated or heat-shrunk, for supply, earth-bonding and battery links.
- PNL
Panel & enclosure wiring
Pre-built loom sets for control panels and enclosures — ferruled, numbered and bundled so panel build becomes assembly rather than wiring.
- OVM
Overmoulded assemblies
Strain-relieved and sealed terminations for assemblies that move, flex or sit in wash-down and outdoor environments.
- KIT
Connector kitting
Housings, contacts and seals supplied matched and counted per assembly, for teams that terminate in-house but struggle to source the parts.
Connector systems we terminate to
72 connector types, sorted into 17 functional groups across 5 families — so a housing sits next to the others that do the same job. If your assembly needs one we do not stock, send the part number and pin count; sourcing the awkward connector is the part of this we are good at.
30 types in Connectors, across 7 groups · 72 total
Board headers & sockets
3DPin fields and sockets that live on the board itself, on a 2.54mm grid and finer.
Ribbon & flat-flex
3DMass termination — the whole cable pressed home in one operation.
Wire-to-board & wire-to-wire
Crimp housings and contacts. The core of most looms.
Data & computer I/O
3DPolarised shells carrying standardised signal sets between equipment.
Sealed circular
3DThreaded barrels sealed against water, dust and vibration.
Audio, video & broadcast
Jacks, plugs and adaptors for audio, video and stage.
DC power & test terminations
Barrel plugs, posts and instrument terminations carrying DC.
Groups collect types that do the same job, and where a group has a 3D model it stands for the whole group rather than one part in it. Exact housings, contact platings, current ratings and pin counts are confirmed against the manufacturer datasheet at quotation — we do not substitute a connector without your written approval.
Rotate it, then check what it mates with
Five representative connector systems you can turn over in 3D. Each one lists the cables that actually mate with it, the sizes it comes in, and where it is normally used — so the connector can be settled before the drawing is.
Representative geometry. Drop a STEP-converted GLB into public/models/ and reference it in src/data/parts.ts to show the real part here.
drag to rotate · scroll to zoom · right-drag to pandrag to rotate · pinch to zoom · two fingers to pan
IDC box header, 2.54mm
Shrouded and keyed box header for flat ribbon cable. Polarised so the assembly cannot be seated backwards.
- Pitch
- 2.54 mm
- Positions
- 10 – 64
- Mounting
- Through-hole
- Termination
- IDC
- Flat ribbon cable (FRC)The standard mate. Conductors sit at half the connector pitch because contacts are staggered across two rows — a 2.54mm header takes 1.27mm ribbon.primary mate · 1.27 mm pitch
- Colour-coded ribbonIdentical construction and pitch, with a repeating colour sequence so conductors can be identified during fault-finding.1.27 mm pitch
- Twisted-pair ribbonAlternating twisted and flat sections. Twisted along the run for noise rejection, flat at the ends so it still mass-terminates normally.1.27 mm pitch
- Shielded ribbonFoil-screened ribbon for runs passing near drives or switching supplies. Needs a drain termination at one end.1.27 mm pitch
- Round-to-flat transition cableRound jacketed for the routed length, fanning into flat ribbon at each end. Used where the run must pass through a gland or conduit.hybrid
Pitch is the one thing that must match exactly. A 2.54mm header will not accept 1.00mm ribbon, and forcing it destroys the IDC contacts.
Cable and conductor types we work with
We work in every common core architecture, on five jacket materials, and specify them against the conditions the finished assembly has to work in. The tool below shows which constructions go together — and says why, in the words an engineer would use. Where heat and flexing are the problem, see high-temperature silicone assemblies.
Build a construction
Three decisions make a cable: how it is built, what protects it, and what it has to survive. Choose any two and the diagram shows you the third.
Hover anything to see what it pairs with. Click to hold a choice and narrow by another column.
From your drawing to a tested assembly
Nine steps in three stages. Every one of them is recorded against the job, so a question three months later has an answer.
Before the build
Understanding the drawing and pricing it honestly.
We read the wire list, connector callouts, gauge, colour code and length tolerances, and come back with questions before quoting rather than after.
On the bench
Cutting, terminating and dressing to the drawing.
Wire cut to length and stripped to the strip length the contact requires, with conductor count verified and no nicked strands.
Before it ships
Proving the assembly, then packing it so it arrives intact.
Continuity and correct pin-out on every assembly, with insulation resistance and hipot where the application requires it.
How every harness is tested before it ships
A harness fails at the termination far more often than in the wire. That is where the inspection effort goes.
Crimp height
Measured with a micrometer against the contact manufacturer's specified range — the single best indicator of a sound crimp.
Pull-force test
Destructive sample testing to confirm the crimp meets the pull-out force the contact is rated for.
Continuity, 100%
Every assembly, every circuit. Confirms the pin-out matches the drawing and there are no opens.
Short and mis-wire
Checks adjacent circuits are isolated and no two pins are transposed — the failure that passes a simple buzz test.
Insulation resistance
Applied where the assembly carries mains or works in a damp environment.
Hipot / dielectric
High-potential withstand testing on request for safety-critical and mains-connected assemblies.
Visual and dimensional
Branch lengths, breakout positions, label placement, sleeving coverage and housing seating checked against the drawing.
First article
A first-off sample submitted for your sign-off before the batch runs, with a dimensional and electrical report.
Traceability
Cable and contact lots recorded against the job, so a field question can be traced back to the material used.
What the work is judged against
Assemblies are built and inspected to these standards, and the acceptance class is agreed per job rather than assumed. We issue the RoHS and REACH declarations an importer needs for their technical file. Ask for the inspection criteria against your drawing and we will confirm them in writing before the batch runs.
- IPC/WHMA-A-620built to
Cable and wire harness assemblies
The harness industry’s workmanship standard: acceptance criteria for crimping, soldering, splicing, lacing, moulding and marking. Class is agreed per job — tell us which one your drawing calls for.
- IPC J-STD-001built to
Soldered electrical assemblies
Solder joint requirements, applied where a drawing calls for soldered terminations rather than crimped contacts.
- EN / IEC 60204-1built to
Electrical equipment of machines
Conductor colour coding, identification and protective bonding for looms going into machinery destined for the EU. Tell us your machine is built to it and we wire to its conventions rather than to general practice.
- RoHScompliant
Directive 2011/65/EU
Housings, contacts, cable and solder specified as RoHS compliant by default, with a written declaration for the parts actually used issued on request — which is what an EU importer needs for their technical file. Say so at enquiry if your application is exempt and needs otherwise.
- REACHcompliant
Regulation (EC) 1907/2006
Substances of very high concern declared against the current ECHA candidate list, for the material actually used on your job. Article 33 information is provided on request at no charge.
- UL 758 AWMcompliant
Appliance wiring material
UL-recognised wire and cable specified where your end product is itself UL listed and the harness has to sit inside that listing.
Standards describe how an assembly is built and inspected, not a substitute for your own drawing. Where your specification is tighter than the standard, your specification governs — send it with the enquiry and we will quote against it.
Industries we build wire harnesses for
The construction changes with the environment — temperature, vibration, wash-down, flex cycles and the approvals the end product has to meet. From India we ship internationally, quoting in INR, EUR or USD against the Incoterm that suits your route.
Send a drawing, get a costed quote
A partial drawing is fine — we would rather ask questions than have you spend a week preparing a package before we have even talked.
- Drawing or sketchEven a hand sketch with lengths marked is enough to start
- Wire list or scheduleFrom-to, circuit numbers, gauge and colour if you have it
- Connector part numbersHousing and contact numbers, or a photo of the mating part
- Cable specificationType, gauge, core count, screening, temperature rating
- Lengths and toleranceOverall length, branch lengths, breakout positions
- Quantity and schedulePrototype count, first batch and expected annual volume
- EnvironmentTemperature, flexing, moisture, chemicals, vibration
- Approvals requiredAny flammability, smoke or sector-specific requirement
Prefer email? Send drawings and wire lists straight to contact@astratechsolutions.in.