Custom Cable and Harness Manufacturer

Custom cables, wire harnesses and cable assemblies for global brands, engineering teams and long-term supply programs.

Cablivo supports overseas cable projects from requirement review, drawing check and sample development to mass production, testing, packaging and shipment coordination. Our team works with project files, old samples, connector models, pinout tables and application details before production starts, helping brands reduce risks in connector matching, wire sequence, material selection and bulk order consistency.

Manufacturing Facts Behind Your Cable and Harness Projects

Cablivo is built for project-based cable manufacturing, not low-end spot cable trading. Our factory scale, production base and engineering workflow support custom cable programs from sample evaluation to repeat orders.

18 +Years Experience

Cablivo works with cable projects where drawing review, sample matching, material discussion and production control matter. Eighteen years in the cable industry helps our team understand common risks in custom cable and wire harness projects, including wrong connector selection, unclear pinout, unstable overmolding, packaging errors and sample-to-production mismatch. Experience is used in project review, not as a simple number.

20000+㎡ Factory

A 20000+ square meter manufacturing base gives Cablivo the space needed for cable preparation, assembly, injection molding, testing, packaging and shipment coordination. For brands managing several cable types or SKU versions, factory space supports better separation between materials, samples, production batches and finished goods.

1500+ Person Team

A 1500+ person team supports engineering, production, purchasing, quality inspection, warehouse, export sales and shipment coordination. For overseas projects, communication does not stop at quotation. Cable length, connector model, AWG, jacket material, label file, packaging file and target quantity need coordinated follow-up before mass production.

3 Manufacturing Bases

Three manufacturing bases help Cablivo support multiple cable projects, repeat orders and long-term supply discussions. Project teams can manage custom cables, wire harnesses, molded cables, power cables, network cables and OEM / ODM cable programs with better production planning and internal coordination.

80+ Molding Machines

More than 80 injection molding machines support molded cable, overmolded cable, connector protection, strain relief and custom plug shape projects. For cable assemblies used in devices, equipment or branded products, overmolding can improve appearance consistency, cable exit protection and connector durability.

MOQ From 500 pcs

MOQ starts from 500 pcs for many custom cable projects. Final MOQ depends on connector type, cable structure, material, overmolding needs, tooling, packaging method and order quantity. Cablivo is better suited for project-based sourcing, trial production, multi-SKU programs and repeat supply, not personal 1–2 pcs orders.

Built for Brands, Engineers and Procurement Teams

Testing scope depends on product type, application and project requirement. Cablivo can discuss electrical, mechanical, appearance and packaging checks before shipment.

Global Brands

Brands need cable and harness products with stable appearance, approved samples, clear labels and packaging files. Cablivo can discuss color, logo position, connector appearance, overmold shape, SKU label, retail box or export carton requirements before production, helping branded cable programs move from sample approval to repeat supply.

Engineering Teams

Engineering teams often send drawings, BOMs, connector datasheets, pinout tables or old sample photos. Cablivo reviews cable length, wire gauge, terminal type, connector direction, polarity, shielding, jacket material and testing points before sampling, reducing avoidable mistakes before tools, components or bulk materials are arranged.

Procurement Teams

Procurement teams need more than a low unit price. They need clear MOQ, sample status, component confirmation, production files, testing scope, packaging details and shipment communication. Cablivo supports quotation based on project details, target quantity, packaging method and required inspection items.

Industrial Manufacturers

Industrial equipment projects often involve stable connection, installation space, wiring sequence, jacket durability and connector fit. Cablivo can help review application conditions, wire length, connector mating parts, terminal requirements and labeling method, supporting custom harness and cable assembly projects for device integration.

Telecom Companies

Telecom and communication equipment projects may require RF cable, coaxial cable, network cable, signal cable, shielded cable or structured cable assemblies. Cablivo can discuss connector model, shielding structure, cable routing, testing requirements and packaging method according to the equipment and target market.

Medical Projects

Medical device cable projects need careful discussion around material selection, connector fit, cable flexibility, cleaning environment, labeling and testing requirements. Cablivo can support project communication and sample development, while certification needs can be confirmed according to product type, target market and project specifications.

Importers & Distributors

Importers and distributors often manage several lengths, colors, connector versions and packaging styles. Cablivo can support SKU list review, barcode labels, carton marks, packing quantity, export cartons and repeat order records, helping reduce mixed SKU, wrong label and warehouse identification problems.

Long-Term Programs

Long-term cable supply depends on approved samples, stable BOMs, clear revision records, production batch control and packaging consistency. Cablivo supports repeat projects through final files, sample references, order records and shipment coordination, helping clients move from first order to future production planning.

Risks Found in Cable and Harness Sourcing

Most cable problems start before production: unclear drawings, wrong connectors, unstable materials or missing packaging files. Cablivo reviews project details early so sampling and bulk production can follow clearer references.

Wrong Connector

A cable assembly may fail even when cable length and wire gauge look correct. Wrong connector series, pin count, direction, locking style or mating part can stop a device from working.

Unclear Pinout

Wire harness projects often fail because wire sequence, polarity, color definition or pin assignment was not confirmed clearly before sampling.

Material Mismatch

PVC, TPE, TPU, silicone and other jacket materials feel and perform differently. Wrong material choice can affect flexibility, appearance, abrasion resistance, temperature behavior and cost.

Sample Difference

A sample may pass basic use, but bulk production can vary if final drawings, BOMs, material references and approved sample records are not locked.

Testing Gaps

Some defects cannot be found by appearance check. Continuity, polarity, short circuit, open circuit, connector fit and pull force may need discussion according to cable type.

Packaging Errors

For branded and multi-SKU cable projects, packaging mistakes can be as serious as product defects. Wrong barcode, SKU label or carton mark can create warehouse and channel problems.

Cable and Harness Products Cablivo Can Manufacture

Cablivo supports a broad range of custom cable and harness projects. Each product can be developed around drawings, old samples, connector requirements, target quantity, application notes and packaging needs.

Send Clear Project Files Before Quotation

A clear RFQ helps Cablivo review feasibility, estimate cost direction and prepare sample discussion more efficiently. Partial information can also start an early engineering conversation.

Files and Details to Prepare

Share as many details as available. A full set of project information helps reduce back-and-forth communication and avoids wrong assumptions before quotation.

When Drawings Are Not Ready

If drawings are not available, Cablivo can start with sample photos, connector close-up images, cable length, device interface photos, quantity and application notes. Our team can help identify missing information before sample work begins.

Drawing or 2D sketch
BOM or component list
Old sample photos
Connector model or datasheet
Pinout table or wire sequence
Cable length and tolerance
Wire gauge / AWG
Jacket material preference
Application environment
Target quantity
Testing requirements
Packaging and labeling needs
Shipping destination

Engineering Review Before Cable Sample Development

Cable and harness projects become easier to control when key details are reviewed before sampling. Cablivo checks product files, structure risks and production feasibility before moving into sample preparation.

Requirement Review

Cablivo reviews application, product function, target quantity, use environment and packaging direction before quotation.

Drawing Review

Drawings are checked for cable length, tolerance, connector direction, wire gauge, pinout, material notes, label position and testing requirements.

Sample Review

Old samples or sample photos help Cablivo understand structure, connector series, overmold shape, wire sequence and packaging style

BOM Review

A BOM helps confirm connector, terminal, cable, jacket, label, packaging and special component requirements before sourcing and sampling.

Connector Check

Connector model, pin count, orientation, mating part, locking structure and availability need confirmation before sample production.

Pinout Discussion

Pinout, wire sequence, polarity and color definition affect function and safety. Cablivo can review pinout tables before sample wiring.

Material Selection

Jacket material affects softness, surface feel, durability, cost and application fit. Cablivo can discuss PVC, TPE, TPU, silicone or other options.

Production File

After sample approval, final files help guide bulk production. These may include approved sample records, final BOM, drawing, label file and packaging file.

Custom Options for Cable and Harness Projects

Custom cable work is not only length adjustment. Cablivo helps review structure, connector, material, label, testing and packaging requirements according to project needs.

Cable Length

Cable length can be confirmed according to installation space, device layout, user handling and packaging limits. Length tolerance should be discussed before sampling, especially for harnesses, equipment cables and multi-SKU programs.

Wire Gauge

AWG affects current capacity, flexibility, cable diameter, cost and processing method. Cablivo can review wire gauge against application, connector size, conductor structure and expected production method before sample development.

Connector Type

Connector type may include USB, DC, RJ45, circular connector, terminal connector, coaxial connector, board connector or project-specific parts. Connector datasheets and mating part photos help reduce mismatch.

Pinout

Pinout confirmation is critical for wire harnesses, data cables, power cables and signal cables. Pin definition, polarity, grounding and wire color should be checked before wiring and testing.

Terminal Type

Terminal selection affects crimping strength, contact stability and assembly fit. Cablivo can discuss terminal model, wire size, crimping method and mating housing before sample work.

Jacket Material

PVC, TPE, TPU, silicone and other materials have different feel, flexibility, appearance and cost. Material selection should match product positioning, use environment and brand expectations.

Shielding Structure

Shielding may be needed for RF, signal, data or industrial cable projects. Foil, braided shield, drain wire and grounding method should be discussed according to signal and equipment needs.

Overmold Shape

Overmold shape affects connector protection, cable exit angle, handling comfort and product appearance. Cablivo can review molded plug shape, strain relief, logo position and tooling needs.

Strain Relief

Strain relief helps reduce stress near connector exits. Bend relief, boot length, material hardness and cable exit direction should be reviewed for handheld, industrial or frequently moved cables.

Cable Color

Cable and connector colors can support brand identity, SKU differentiation or installation recognition. Color references should be confirmed with material type, sample approval and production feasibility.

Logo and Label

Logo can be molded, printed or placed on label depending on material, connector shape and product style. Cablivo can discuss logo position, size, method and durability expectations before sampling.

Packaging

Packaging may include bulk packing, OPP bag, poly bag, retail box, insert card, barcode label, SKU label and export carton. Packaging files should be reviewed before bulk production.

Wire Harness Manufacturing for Equipment and Devices

Wire harness projects need clear structure, branch layout, terminal crimping, connector matching and testing. Cablivo supports custom harness development from sample review to bulk production.

Cable Assembly Manufacturing From Sample to Production Short Description

Cable assemblies combine cable, connectors, terminals, shielding, soldering, crimping and packaging. Cablivo supports project communication from design review to approved sample and repeat production.

Molded Cable Support With In-House Molding Capacity

Overmolding helps protect connectors, improve product appearance and create a more stable cable exit structure. Cablivo supports molded cable projects with 80+ injection molding machines.

Material and Structure Choices for Cable Programs

Cable material and structure affect flexibility, appearance, durability, shielding and cost. Cablivo can discuss material direction according to product positioning and application environment.

PVC Jacket

PVC is widely used for many cable types due to cost control, process stability and broad application range. It can be considered for standard power cables, data cables, device cables and many OEM cable programs.

TPE Jacket

TPE can provide softer hand feel and more flexible handling. It may be considered for consumer-facing cable products, device connection cables and projects where touch, flexibility and appearance are important.

TPU Jacket

TPU can support better wear resistance and a premium surface feel in selected projects. It may fit cables needing stronger jacket protection, cleaner appearance or improved handling experience.

Silicone Jacket

Silicone can be considered for cables requiring soft bending behavior and a special tactile feel. Application environment, processing method and cost should be reviewed before choosing silicone.

Copper Conductor

Conductor selection affects current capacity, flexibility and cable diameter. Cablivo can discuss conductor structure and wire gauge according to power, signal, installation and handling requirements.

Shielding Layer

Shielding can help signal, data, RF and industrial cable projects manage interference-related risks. Foil, braid, drain wire and grounding method should be confirmed according to actual application.

Insulation Structure

Insulation structure affects electrical performance, processing method and cable diameter. Cablivo can review conductor, insulation and jacket requirements before moving into sample development.

Outer Appearance

Cable appearance includes jacket color, surface texture, connector finish, overmold shape, logo and label position. These details are important for branded products and long-term SKU consistency.

Sample Development Before Bulk Cable Production

A cable sample is not only a display piece. It becomes the reference for connector matching, function checking, appearance review, material confirmation and future production files.

Requirement Review

Cablivo reviews application, product type, target quantity, connector requirement, cable length, AWG, packaging method and testing expectations. Missing details are listed before sample work starts.

Drawing and Sample Check

Drawings, BOMs, old samples or sample photos are checked for cable structure, connector model, pinout, jacket material, label position and possible production risks.

Connector and Material Confirmation

Connector model, terminal, cable, jacket material, color, overmold direction and packaging method are discussed before sample preparation. Component availability can also affect sample planning.

Prototype Preparation

After key details are confirmed, Cablivo prepares a sample for review. Sample planning depends on structure, component availability, tooling needs and project complexity.

Test and Revision

Samples can be checked for length, connector fit, pinout, polarity, appearance, label and other agreed items. Revisions are recorded so the next sample version is clearer.

Approved Sample

The approved sample helps guide production together with the final BOM, drawing, material reference, label file, packaging file and testing checklist.

Production Process for Power Cable Assemblies

Power cable production may include cutting, stripping, crimping, soldering, overmolding, assembly, testing, labeling and packaging, depending on cable structure.

Typical production flow:

Testing and Inspection Points for Cable Projects

Testing scope depends on cable type, application and project risk. Cablivo can discuss inspection items before production so key electrical, mechanical, appearance and packaging risks are reviewed.

Continuity Test

Continuity testing helps confirm electrical path connection and can detect open circuits. It is commonly discussed for cable assemblies, wire harnesses, power cables and device connection cables.

Pinout Check

Pinout check confirms wire sequence and signal assignment. It is important for harnesses, data cables, device cables and custom connector assemblies with multiple pins.

Polarity Check

Polarity check helps reduce wrong positive and negative connection risks. It is especially important for power cables, DC cables, battery cables and equipment connection projects.

Short Circuit Check

Short circuit check helps detect unwanted electrical contact between conductors. It is useful for multi-core cables, harnesses, molded cables and assemblies used in equipment.

Open Circuit Check

Open circuit check helps find broken conductors, missed crimping or poor internal contact. It can be discussed for wire harnesses and assembled cables before shipment.

Connector Fit

Connector fit check confirms whether the connector mates with the intended socket or mating part. Photos, samples or mating connectors can help during early project review.

Pull Force Test

Pull force discussion may be needed for terminals, crimped connections and strain relief areas. Required test method depends on cable type, terminal style and project expectation.

Bending Review

Bending review may apply to cables used in frequent movement or tight installation spaces. Jacket material, conductor structure and strain relief design can affect bending behavior.

Visual Inspection

Visual inspection checks appearance, color, overmold shape, connector condition, label position, surface marks and packaging cleanliness before shipment preparation.

Packaging Check

Packaging check covers SKU label, barcode, carton mark, packing quantity and packaging style. It is important for private label, distributor and multi-SKU cable programs.

Packaging and Labeling Support for Cable Programs

Packaging is part of cable project control. Cablivo can support bulk packing, private label packaging, SKU labels, barcode labels, carton marks and export cartons according to order needs.

MOQ and Order Planning for Custom Cable Projects

Custom cable and harness orders need clear project planning. MOQ, sampling, tooling, component availability and packaging method can affect quotation and production discussion.

MOQ From 500 pcs

MOQ starts from 500 pcs for many custom cable projects. Final MOQ depends on connector type, cable structure, material, overmolding requirement, tooling need, packaging plan and total order quantity. Cablivo is better suited for project-based sourcing than personal small orders.

Sample Planning

Sample planning starts after key details are reviewed, such as drawing, connector model, cable length, AWG, pinout, material and packaging direction. Sample schedule should be confirmed after component availability and project complexity are reviewed.

Bulk Production

Bulk production planning depends on final BOM, approved sample, material preparation, production process, testing scope, packaging files and order quantity. Delivery schedule should be confirmed according to product structure and production arrangement.

Repeat Orders

Repeat orders become more stable when approved samples, revision records, SKU labels, packaging files and order history are managed clearly. Cablivo can support long-term cable supply discussions for brands, distributors and equipment programs.

Cable and Harness Support Across Key Industries

Custom cable and harness projects appear in many product and equipment categories. Cablivo can discuss structure, material, connector, testing and packaging needs according to application requirements.

Real Manufacturing Process Behind Cable Projects

Cablivo’s cable manufacturing process connects material preparation, assembly, molding, testing and packaging. Factory evidence should help clients understand how project files become finished cable products.

Material and Cable Preparation

Cable projects start with material and semi-finished cable preparation. Conductor structure, insulation, jacket material, shielding and cable diameter need to match the final application and assembly method.

Assembly and Termination

Assembly work may include cable cutting, stripping, terminal crimping, soldering, connector assembly, sleeve placement, shielding termination and label application according to product structure.

Molding and Strain Relief

Molded cable projects use injection molding to form connector protection, strain relief and custom plug shapes. Overmolding details should be checked through samples before bulk production.

Inspection Before Packing

Inspection connects product quality with packaging accuracy. Cable length, connector fit, pinout, appearance, label, SKU and packing method can be checked according to agreed project requirements.

Packaging and Shipment Coordination

Packaging may include individual bagging, labels, retail packaging, export cartons, carton marks and packing lists. Shipment coordination follows confirmed order quantity, carton arrangement and destination needs.

Cable Project Cases Without Client Name Disclosure

Many cable and harness projects involve confidential drawings, private labels or equipment details. Cablivo can explain project handling through anonymized case examples.

Industrial Harness Case

Project Type: Industrial equipment wire harness Challenge: The old sample had unclear wire sequence and several connector branches. Cablivo Support: Our team reviewed sample photos, connector positions, wire colors, branch length and label needs before sample work. A pinout discussion helped reduce wiring errors. Result: The approved sample became the reference for bulk production files, harness labels and inspection points.

Private Label Cable Case

Project Type: Branded cable assembly Challenge: The client needed consistent connector color, cable surface, logo position, barcode label and retail packaging. Cablivo Support: Our team reviewed artwork, cable samples, packaging size, SKU label and carton mark requirements before production. Result: Product appearance, packaging file and label information were aligned before bulk order discussion.

Multi-SKU Distributor Case

Project Type: Multi-length cable program Challenge: Several lengths, colors and connector versions created mixed SKU and wrong label risks. Cablivo Support: Cablivo reviewed SKU list, label file, carton mark format and packing quantity before shipment preparation. Result: SKU separation, packaging notes and carton identification became clearer for warehouse receiving and repeat order management.

Why Customers Trust Tianxiaowei

Real customer feedback and cooperation moments that reflect our product quality, responsive service, and
long-term manufacturing support.

Certificates & material control

FAQ About Custom Cable and Harness Manufacturing

These answers help clarify project communication before quotation, sampling or bulk production discussion. More detailed review can begin after drawings, sample photos or BOM files are shared.

What is the difference between custom cable and wire harness manufacturing?

Custom cable manufacturing usually focuses on cable length, connector assembly, termination, jacket material, shielding, molding and functional testing. Wire harness manufacturing often involves multiple wires, branches, terminals, connector housings, labels, sleeving and installation layout. Many equipment and device projects need both cable assembly and harness thinking, so Cablivo reviews structure, pinout, connector model and application before sample work.

Can Cablivo manufacture both cable assemblies and wire harnesses?

Yes. Cablivo supports custom cables, wire harnesses, cable assemblies, molded cables, overmolded cable assemblies, power cables, USB cables, RF / coaxial cables, network cables and industrial cable projects. The exact production route depends on drawings, samples, connector models, AWG, materials, testing points, packaging method and target order quantity.

What files should I send before quotation?

Recommended files include drawing, BOM, old sample photos, connector model, pinout table, cable length, wire gauge, application notes, target quantity, testing requirement and packaging plan. If drawings are not available, close-up photos of connectors, cable ends, labels and application environment can help Cablivo start early review.

Can you review drawings, BOMs or old sample photos?

Yes. Cablivo can review drawings, BOMs, old sample photos and connector information before sample discussion. Review points may include cable length, AWG, connector direction, terminal model, wire sequence, jacket material, shielding, label position, packaging and testing requirements.

What is the MOQ for custom cable and harness projects?

MOQ starts from 500 pcs for many custom cable projects. Final MOQ depends on connector type, cable structure, material, overmolding requirement, tooling need, packaging method and order quantity. For multi-SKU programs, MOQ should be discussed by SKU version and total project quantity.

Can Cablivo support prototype samples before bulk production?

Yes. Prototype samples can be discussed after key details are reviewed. Sample work usually requires connector confirmation, cable length, AWG, pinout, material direction, appearance requirement, testing points and packaging expectations. Sample preparation depends on component availability, project structure and whether tooling is required.

How do you reduce sample-to-production mismatch?

Cablivo connects approved samples with final drawings, final BOM, material references, label files, packaging files and testing checklists. Before bulk production, key points such as cable length, connector, pinout, appearance, overmold shape and packaging style can be confirmed against agreed references.

Can you support overmolded cable assemblies?

Yes. Cablivo has 80+ injection molding machines supporting molded cable and overmolded cable projects. Overmolding can be discussed for connector protection, strain relief, custom plug shape, cable exit direction, logo position and improved product appearance. Tooling needs should be confirmed during engineering review.

What testing can be discussed before shipment?

Testing may include continuity, pinout, polarity, short circuit, open circuit, connector fit, pull force, bending review, visual inspection and packaging inspection. Exact testing scope depends on cable type, application, project risk and agreed requirements before production.

Can you support private label cable packaging?

Yes. Cablivo can discuss molded logo, printed label, barcode label, SKU label, OPP bag, poly bag, retail box, color box, insert card, carton mark and export carton requirements. Packaging files should be confirmed before bulk production.

Can you manage multi-SKU cable programs?

Yes. Multi-SKU projects can be reviewed by length, color, connector version, packaging style, barcode and carton mark. SKU list, label files and packing quantity should be confirmed before production to reduce mixed SKU and warehouse identification risks.

Can Cablivo support industrial or medical cable projects?

Cablivo can support industrial cable projects and medical device cable project communication. Material, connector, flexibility, labeling, testing and packaging needs should be reviewed according to application. Certification or special compliance requirements need to be confirmed based on product type, target market and project specification.

Do you sign NDA for custom cable projects?

NDA discussion can be arranged for projects involving confidential drawings, product designs, private label packaging, connector specifications or long-term supply programs. Sensitive client files should be shared through proper communication channels after business terms are aligned.

How do I start a custom cable and harness project?

Start by sending drawings, sample photos, BOM, connector model, pinout table, cable length, AWG, application, quantity, testing requirement and packaging needs. Cablivo will review available details and help confirm the next step for quotation, sample development or bulk production discussion.

Start Your Custom Cable and Harness Project With Cablivo

Send drawings, sample photos, BOM, connector model, cable length, AWG, target quantity, testing needs and packaging files. Cablivo can review project details before quotation, sampling or bulk production discussion.