Cable and Wire Harness Manufacturing
INDIC offers cable and wire harness manufacturing to IPC/WHMA-A-620 for OEMs that want one supplier for the board, the harness and the enclosure. INDIC builds multibranch, high-density 3D harnesses up to 2,500 points, plus optical-fibre and hybrid harnesses, and integrates them with its PCBA and box-build lines.
- IPC/WHMA-A-620 Class 2, Class 3 on request
- Up to 2,500 points
- 100% electrical testing
- Harness, PCBA and box build
| 2,500 points | Maximum points per high-density harness |
|---|---|
| Class 2 / Class 3 | IPC/WHMA-A-620 workmanship (Class 3 for aerospace or on request) |
| 100% | Of harnesses electrically tested |
| Since 2007 | Manufacturing electronics in Bengaluru, India |
Cable and Wire Harness Manufacturing for Three Harness Types
INDIC builds everything from point-to-point cable assemblies to dense, multi-branch 3D looms in copper, fibre or both.
| Harness type | Description | Standard or limit |
|---|---|---|
| Multibranch cable and wire harnesses | Branched looms that route power and signal across a product or vehicle, labelled, sleeved and connectorised to drawing | IPC/WHMA-A-620 Class 2; Class 3 on request |
| High-density and 3D harness assemblies | Complex harnesses built in three dimensions to match the installed shape inside an enclosure or chassis | Up to 2,500 points |
| Optical-fibre and hybrid harnesses | Fibre harnesses and hybrid wire/fibre looms with bend-radius and strain-relief control | IPC/WHMA-A-620 Class 2/3 |
Process Controls in Our Cable and Wire Harness Manufacturing
Most harness failures are intermittent opens and shorts at a crimp, splice or seal. INDIC controls each of these on the line.
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Precision crimping and splicing
INDIC uses automotive-grade crimping with crimp-force monitoring on every cycle, precise cut and strip, and consistent splicing practice to IPC/WHMA-A-620.
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Ultrasonic welding, spot welding and braiding
Ultrasonic welding creates strong, low-resistance splices without solder. Braiding adds abrasion protection and EMI shielding.
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Potting, over-moulding and low-pressure moulding
INDIC seals connectors and splices against moisture, dust and vibration, and adds moulded strain relief that extends connector life.
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100% electrical testing
INDIC tests every harness for continuity and polarity, with hi-pot and insulation-resistance testing where required. See electrical testing.
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Full traceability
INDIC ties each harness ID to the serial number of the finished product, and production checkpoints block a unit until its tests pass. See test data traceability.
Cable and Wire Harness Manufacturing Integrated with PCBA and Box Build
Buying harnesses and boards from separate vendors adds hand-offs, separate minimum order quantities and weeks of coordination. One INDIC program team owns all three stages.
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PCB assembly
SMT, THT, BGA and hybrid PCBAs tested with ICT and FCT.
PCB assembly services -
Cable and wire harness
Harnesses built, tested and traced to the same unit record as the boards.
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Box build
Enclosure fit, harness routing, system integration and end-of-line test, with fit checked before the enclosure is closed.
Custom box build
INDIC harnesses already run inside high-voltage EV assemblies
| Application | Harness work INDIC delivers |
|---|---|
| EV and high voltage | Harness sub-assemblies in HV battery junction boxes, EV power distribution units and HV AC/DC connectors (see e-mobility) |
| Automotive | Harness-to-motor mechanical integration under IATF 16949 (see automotive electronics manufacturing services) |
| Solar and industrial | Cable assemblies for solar systems and industrial equipment (see solar electronics manufacturing) |
| Aerospace and defence | Class 3 harnesses on request |
INDIC builds harnesses to four recognised standards
| Standard | Scope |
|---|---|
| IPC/WHMA-A-620 | Cable and wire harness assembly: Class 2 standard, Class 3 for aerospace or on request |
| IPC-A-610 | Acceptability of the electronic assemblies the harness connects to |
| IATF 16949:2016 | Automotive quality management system |
| ISO 9001:2015 | Quality management system |
Further reading: wire and cable harnessing for complex PCBA and box builds and what OEMs should check in harness integration.
Cable and wire harness manufacturing questions
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What IPC/WHMA-A-620 class does INDIC build wire harnesses to?
INDIC builds to IPC/WHMA-A-620 Class 2 as standard. Class 3 is available for aerospace programs or on customer request.
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How complex a wire harness can INDIC build?
INDIC builds multibranch harnesses and high-density 3D harness assemblies of up to 2,500 points. It also builds simpler point-to-point cable assemblies.
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Can INDIC make optical-fibre and hybrid harnesses?
Yes. INDIC builds optical-fibre harnesses and hybrid wire/fibre looms. Bend-radius and strain-relief controls protect signal integrity.
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How does INDIC test cable and wire harnesses?
INDIC electrically tests 100% of harnesses for continuity and polarity, adding hi-pot and insulation testing where the application requires it. Each harness ID is traceable to the finished product's serial number.
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Can INDIC seal harnesses for harsh environments?
Yes. INDIC offers potting, over-moulding and low-pressure moulding to seal connectors and splices against moisture, dust and vibration. Braiding adds abrasion protection.
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Can I source cable and wire harness manufacturing, PCBAs and enclosures from one supplier?
Yes. One INDIC program team owns the PCBA, the harness and the box build. The customer gets one schedule, one point of contact and one traceability record for the whole product.
Need harnesses built alongside your boards?
Send INDIC your harness drawings, wire list and volumes, plus PCBA and enclosure details if you want one supplier for the full build.
