Wire Harness and Cable Assembly Manufacturing

Capabilities

Capabilities

SAISONIC was founded in 1992. Over nearly 33 years of steady growth, we have become a leading provider and partner for wire harnesses and cable assembly solutions. Our factory is located in Dongguan, China, covering 8,016 m² of land with more than 30,000 m² of building space. We have a team of over 450 employees, including 7 sales professionals, 10 R&D engineers, 340 operators, 36 quality staff, and more than 60 in management. Our facility includes 10 wire harness production lines and 3 cable assembly lines, producing over 8 million wire harnesses and 600,000 cable assemblies every month. We provide both rapid prototyping and large-scale production, with flexible delivery options to meet your project needs.

Raw Materials Area

SAISONIC holds ISO9001 and ISO14001 certifications for quality and environmental management. Our quality team, which includes IQC, OQC, QC, and other specialists, oversees the entire production process. From raw material purchasing and incoming inspections to storage and final output, we ensure full quality control and manage hazardous substances. We perform process checks, first-piece inspections, and last-piece inspections. Raw materials are stored under controlled temperature and humidity, following the first-in-first-out (FIFO) principle. Our advanced ERP system allows us to track every step of production for both wire harnesses and cable assemblies.

Wire Harness and Cable Assembly Manufacturing

Wire Harness and Cable Assembly Processing Workflow

Wire Cutting

SAISONIC operates 18 fully automatic computerized wire cutting machines. These machines allow setting wire length, diameter, stripping length, and production quantity in the program. They also automatically control wire feeding, cutting, and stripping, with length accuracy within ±0.5 mm, processing thousands of wires per hour.

Wire Stripping

We have 18 machines for automatic stripping, manual stripping, and combined cutting/stripping, capable of handling all types of wire stripping and cutting services.

Wire Crimping

SAISONIC operates 67 crimping machines, including fully automatic (SCM), semi-automatic, and manual units. We serve demanding industries such as automotive, aerospace, medical, consumer electronics, and home appliances. Every crimped product undergoes rigorous quality checks, including tensile testing, crimp height monitoring, and microsection analysis, ensuring that all products meet industry standards.

Wire Soldering

We use automatic soldering machines, manual soldering, and wave soldering techniques. X-ray inspection is used to make sure there are no cold solder joints, shorts, pinholes, excessive flux, or deformations. This ensures that all custom wire terminations meet your project requirements.

Wire Termination – Connector Assembly

Connector assembly is the final step that brings together all previous processes—cutting, stripping, crimping, and soldering. With strict procedures and multiple quality checks, we guarantee that every wire harness we deliver is fully functional.

Assembly

Includes tape wrapping, cable tie installation, component mounting, assembly, and potting.

Cable Overmolding / Injection Molding

Overmolding lowers costs, provides strain relief at cable ends, and extends the service life of cable assemblies. SAISONIC operates 22 injection molding machines, supporting materials like PVC, TPR, TPE, and offering a variety of colors and shapes.

Types of Custom Overmolded Cable Assemblies

Ferrite cores (single/dual)

Transition molds (T-mold/Y-mold)

Audio connectors (banana plug jacks, DC power plug jacks, 3.5 mm stereo plugs)

Strain relief

Circular connectors (M8/M12 cables)

Right-angle molded assemblies

Cable Overmolding

Wire Harness Testing – Continuity / Hi-Pot Testing

Continuity testing ensures all wires are connected properly with resistance ≤ 0.1 Ω. Insulation resistance testing is conducted at 500 VDC, verifying insulation between wires and between wires and the housing meets standards.

Appearance Inspection

At this step, the overall condition of the harnesses and cable assemblies is inspected: no damage, breaks, or exposed wires; terminals free from oxidation, deformation, or incomplete insertion; connectors clean; wire labels clear and correctly placed. Inspection methods include magnifier checks and X-ray inspection.

Packing

After passing all inspections, wire harnesses and cable assemblies are packaged following standard operating procedures (SOP) and stored in the finished goods warehouse until shipment.

Quality Assurance

(Wire Harness and Cable Assembly Testing Equipment)

Cable and Wire Bending / Swing Test

This test simulates mechanical stress such as bending and swinging that wires experience during actual use, assessing their durability and reliability.

Test Standards
1. IEC 60884-1: For plugs and sockets used in household and similar applications. Test angle: 90°, hanging weight: 1–2 kg (depending on wire cross-section), 10,000 cycles, speed: 60 cycles/min.
2. GB/T 2099.1: Equivalent to IEC 60884-1, specifies rated current, voltage, and acceptance criteria (e.g., break rate ≤10%).
3. UL817: For power cords; supports 360° bending, weight: 50–500 g, speed: 60 cycles/min.
Test Parameters
1. Angle Range:
2. Standard: 90° (power cords)
3. Limit: 180° or 360° (mechanical cables, high-load applications)
1. Speed & Cycles:
2. Standard test: 60 cycles/min, 10,000 cycles (power cords) or 20,000 cycles (IEC connectors)
3. High frequency test: up to 5Hz (360° extreme test)
1. Load Conditions:
2. Wire cross-section ≥0.75mm² → hanging weight: 2kg
3. Wire cross-section <0.75mm² → hanging weight: 1kg

Terminal Profile Analyzer

(3D Imaging and Precise Measurement for Crimping)

Microscope magnification: 0.75× – 4.5×
Total video magnification: 40–260×
Zoom ratio: 6.5:1
Working distance: 100 mm
Travel range: 250 mm
2D mechanical stage with ball-bearing guide, platform size: 180×155×26 mm, moving range: 75×55 mm, glass turntable diameter: 95 mm
Imaging system: SONY video system (Japan)
Measurement accuracy: 0.001 mm
Lighting: Full white LED illumination

Coordinate Measuring Machine (CMM)

Measures the dimensions of parts along X, Y, and Z axes, including height, width, and depth, using coordinate-based technology.

Cable Non-Migration Test

This test follows general standards (e.g., Sony). A 2.5 mm thick test plate (400×400 mm) is used. After placing the sample between two plates at 60 °C for 24 h and applying a 500 g (or 200 g) weight, the test plate is examined visually. No marks or migration indicate a pass.

* “Migration” refers to impressions left on the test plate.

Air Tightness / Leak Detector

Testing the sealing of wire harnesses to ensure there is no gas leakage that could cause failure. Standards include ISO 6722, JIS D 0203, and ISO 9170-1.

Wire Harness Comprehensive Tester – Continuity / Insulation / Hi-Pot Testing

Continuity Test: applies current to the harness or assembly; measures voltage and current at cable ends to calculate resistance (Ohm’s Law). Compares measured resistance to set values to ensure compliance.
Insulation Test: applies high voltage between wires and grounding lines; checks current flow to determine if insulation meets standards.
Hi-Pot Test: applies high voltage for a set time and measures current. If current exceeds preset limits, the harness fails. Measures insulation resistance and displays results.

RoHS 1.0 Analyzer – SHIMADZU X-Ray Fluorescence Spectrometer (XRF)

Uses secondary X-rays emitted when materials are irradiated with high-energy X-rays or gamma rays to determine elemental composition.

RoHS 2.0 Analyzer – SHIMADZU GC-MS (Gas Chromatography–Mass Spectrometry)

Identifies and quantifies chemical substances in components and determines molecular structure and chemical properties. GC separates volatile components, and MS detects and measures them.