Custom wire harness manufacturing is more than bundling wires—it's engineering performance, precision, and trust into every connection. At Celestix Industries India Pvt. Ltd., we take this journey from wire harness prototype to production seriously, because our customers’ systems depend on it.

Why Tailored Wire Harnesses Matter

In modern electronics—whether it’s electric vehicles, industrial automation systems, medical equipment, aerospace, or smart appliances—a wiring harness is the central nervous system. It ensures stable power and signal transmission across critical components. A substandard harness could mean a malfunctioning BMS in an EV, interference in smart refrigerators, or downtime in robotic arms—failures that industries can’t afford.

Tailored wire harnesses go beyond one-size-fits-all configurations. They are precision-engineered to meet the demands of specific operating environments, electrical loads, and spatial constraints. For mission-critical industries, tailored solutions provide the confidence needed to scale.

From startups building their first modular wire harness prototyping to global OEMs managing complex wire harness production, the demand for tailored wiring harness solutions is growing. And with it, the need for a partner who brings technical clarity, manufacturing agility, and an unwavering commitment to quality.

That’s why at Celestix, every wire harness begins with one principle: engineering certainty into complexity.

Phase 1: Engineering the Prototype

Design for Manufacturability & Application

At the prototype stage, our engineering team works closely with your design—no matter how complex or compact. We assess:

1. Routing paths for EMI/thermal/humidity resistance
2. Material selection, including:

3. Connector layout for modularity and minimal failure points
4. Crimp profile analysis and CAD modeling using Siemens NX and EPLAN

Whether you're creating an EV wire harness prototype design, a production-ready aerospace wire harness model, or an ISO 13485-compliant medical harness prototype, our engineering process incorporates Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.

Additional Design Considerations:

• Poka-yoke harness assembly process

• Total Cost of Ownership (TCO) analysis

• Custom and gold-plated connector harness production

• Stress distribution simulations using 3D CAD

• Ingress protection (IP67, IP69K) considerations for harsh environments

We deliver prototypes in 1–2 weeks—optimized, testable, and scalable.

This approach supports rapid wire harness prototyping, ensuring reliability before scaling.

Phase 2: Rigorous Validation and Testing

Each prototype is validated through a rigorous, multi-point testing process:

1. Continuity and High-Voltage Testing (Hipot testing)

2. Crimp Cross-Section Analysis

3. Strain Relief and Pull-Force Evaluation

4. HALT Testing (Highly Accelerated Life Test)

5. Thermal Cycling, Corrosion Resistance, UV Testing

6. Vibration Testing for aerospace and mobility sectors

We also use digital twin wire harness design simulations to verify real-world accuracy.

Additional validation includes:

• Wire Harness Failure Mode and Effects Analysis (FMEA)

• Reverse Polarity Testing

• Resistance and Voltage Drop Mapping

• Traceability with barcoding and serialization

All validation is aligned with:

• IPC/WHMA-A-620 standards

• AS9100 wire harness manufacturing guidelines

• ISO 13485 for medical equipment

This level of validation is critical for mission-critical applications, such as aerospace avionics, EV BMS systems, and patient-connected medical devices.

Phase 3: Production-Ready Transition

Upon validation, production ramps up using:

1. Automated Harness Production: Cutting, stripping, crimping, and laser marking

2. Robotic Harness Assembly for repeatability and quality

3. Advanced Overmolding & Braided Shielding for rugged environments

4. ERP-Based Traceability: Lot-wise data, certs, and reports

5. VMI Supply Chain Systems: Consistent just-in-time component flow

Applications supported:

• Aluminum wire harness manufacturing

• Fluoropolymer & LSZH harness production

• Custom insulation protection harness manufacturing

• High-temperature harness prototyping

• Vibration-resistant harness manufacturing

Our processes are compliant with:

ISO 9001, IATF 16949, ISO 45001, RoHS, REACH, UL, CE, BIS, ISO 14001, ISO 6722, IEC 60228

Why Celestix?

Our commitment to quality and flexibility makes us a preferred B2B tailored harness supplier:

1. End-to-End Solutions: From concept to global delivery

2. Certified Wire Harness Prototyping: IPC, IATF 16949, UL, CE, RoHS, REACH

3. Custom Tooling: Molded connectors, sealed housing, overmolding

4. Robust Quality Control Systems: Visual, electrical, and automated

5. Integrated Logistics & VMI: Seamless procurement and delivery

6. Risk Mitigation & DFMEA: Early detection and prevention systems

7. Dedicated In-House Testing Lab: HALT, Hipot, Vibration, Thermal Cycle

8. Global Reach with Local Agility: Serving OEMs across India, Europe, and North America

Industries served:

• Automotive Wire Harness Prototyping

• Medical Wire Harness Manufacturing

• Industrial Harness Development

• Aerospace & Defense Harness Solutions

• Consumer Electronics Harness Integration

Case in Point: EV Manufacturer Turnaround

Challenge: Thermal instability & EMI in EV battery harnesses
Solution:

• Lightweight Al-Cu high-reliability harness

• IP67-rated overmolded shielding

• Optimized CAD layout via EPLAN tools

• Rapid deployment within 5 weeks

Results:

• 20% faster charging

• 15% lighter harness

• 100% traceability for compliance

The Future of Harnessing Innovation

Celestix continues to invest in:

1. Smart Harnesses with embedded sensors

2. AI-driven Quality Control

3. Digital Twin Prototyping & Simulation

4. Expanded Automation for scalability

5. Green Manufacturing aligned with RoHS, REACH, and ISO 14001

6. Advanced CAD Tools like Siemens NX, EPLAN, and AutoCAD Electrical

7. Predictive Maintenance via Data-Enabled Harness Systems

8. Scalable, modular harness platforms for multiple SKUs

Whether you need:

• IP67 automotive cable assemblies

• PTFE aerospace wiring solutions

• ISO-certified medical-grade wiring

• High-density industrial wire looms

Ready to Start?

Let’s take your concept from prototype to production with unmatched quality, reliability, and speed.

Email Us: info@celestixindustries.com
Request a Quote: celestixindustries.com/GetaQuote
Visit Us: Pune, Ahmedabad, Greater Noida — serving global OEMs with scalable precision

Have Questions? Our engineering team is ready to guide you through DFM options, alternative materials, or rapid turnaround prototyping, tailored to your specific timeline.

Need It Fast? We support urgent builds with dedicated rapid-response manufacturing cells.

Want to Validate First? Request a prototype with full test documentation, traceability, and compliance reports.

Celestix Industries — Engineered to Perform. Built to Last.