In today’s technology-driven world, where vehicles drive themselves, robots manage factory floors, and smart appliances anticipate user needs, wire harnesses are the silent heroes. They channel power and signals across systems with absolute reliability—and behind every reliable harness is a manufacturing process grounded in engineering discipline, quality systems, and domain expertise.

At Celestix Industries India Pvt. Ltd., a leading custom wiring harness manufacturer based in Pune, we approach wire harness fabrication as a mission-critical discipline, not a commodity. We are not resellers—we design, build, test, and deliver world-class wire harness manufacturing solutions in India under one roof. With certifications like IATF 16949, IPC/WHMA-A-620, ISO 9001, and UL, we bring a zero-compromise approach to quality, scalability, and customization. Our in-house lab, skilled IPC-certified operators, and end-to-end process control set us apart as a globally trusted manufacturing partner.

Why Choose Celestix?

• 100% in-process and final QC – Every harness undergoes stage-by-stage and final testing to eliminate defects.

• Certified (ISO 9001, IATF 16949, UL, CE, BIS) – Verified for global and industry-specific compliance.

• Scalable capacity – 5–6× annual growth – Ready to support OEM ramp-ups and seasonal demands.

• In-house lab and overmolding capability – Control over testing, tooling, and ruggedized sealing.

• Flexible for low or high volume – Ideal for prototyping or mass production.

• Located in Pune, India – globally shipping – Cost-effective access to domestic and international markets.

• DRIVE Culture: Dedication, Respect, Integrity, Value, Excellence – A people-first philosophy ensuring long-term collaboration.

• Custom engineering support – DFM/DFA advisory for optimized production.

• Rapid prototyping turnaround – To shorten development cycles.

• Global component sourcing network – Ensures continuity and BOM accuracy.

• In-house training and upskilling – IPC-certified workforce trained on the latest techniques and standards.

• End-to-end traceability systems – Every component is tracked through the supply chain for reliability.

Our philosophy is rooted in engineering precision, operational agility, and deep industry collaboration. We thrive in demanding environments where wiring reliability is paramount—from high-voltage EVs and mission-critical medical devices to aerospace-grade assemblies and industrial automation systems. We support OEMs and contract manufacturers in navigating the complexity of custom wire harness design, ensuring robust wire harness reliability across various sectors.

In parallel, we understand the expectations of B2B wire harness procurement professionals. They require partners who can deliver wiring harness manufacturing solutions on time, within budget, and with transparency. That’s why we have robust systems for wire harness supply chain visibility and optimized lead-time forecasting. We work collaboratively with sourcing teams to offer full documentation, including PPAP, FMEA, Control Plans, and compliance declarations.

What Is Wire Harness Fabrication?

Wire harness fabrication is the process of assembling various components to build structured electrical connectivity systems. These systems integrate:

1. Conductors – carry current (e.g., copper, aluminum)

2. Insulators – protect and shield (e.g., PVC, PTFE)

3. Terminals and connectors – interface with systems (e.g., Molex, TE)

4. Protective coverings – shield from environment (e.g., conduit, braid)

This process is essential for:

• Automotive wire harness routing and power distribution

• Aerospace wiring harness shielding and reliability

• Electrical wiring harness used in consumer appliances and control panels

Wire harness fabrication also involves strain relief techniques, bend radius calculations, and routing simulations to ensure long-term durability and ease of integration.

Core Stages of Wire Harness Fabrication

Additional processes may include soldering (per J-STD-001), overmolding, and shielding braid application, depending on environmental requirements.

Each step incorporates wire harness quality control and aligns with IPC/WHMA-A-620 standards to ensure consistency, safety, and durability.

Why Custom Wire Harnesses Matter

Off-the-shelf harnesses rarely meet the demands of modern OEMs. That’s why we specialize in custom wire harness design to suit:

• Specific voltages, currents, and signal types

• Environmental conditions (vibration, moisture, temperature)

• Compact or high-flex routing constraints

• Regulatory standards (UL, CE, RoHS, ISO)

• Custom labeling, pin mapping, and connector locking

This level of customization enables better wire harness risk management, cost reduction through DFM/DFA, and superior performance in the field. It also enhances assembly line integration, reducing downstream errors and installation time.

Design and Engineering Excellence

Our process begins with collaborative design. Key inputs include:

1. Electrical schematics and layouts

2. Mechanical constraints and routing paths

3. Functional safety or shielding needs

4. Durability or lifecycle expectations

We use:

• Wire harness CAD design tools (AutoCAD, EPLAN)

• Wire harness digital twin simulations

• 3D harness prototyping for design reviews

• Predictive analytics for failure modes and life-cycle performance

• Component de-rating analysis for long-term reliability

This ensures that the final product is optimized for production and end-use.

Selecting the Right Materials

Here’s a snapshot of material choices and their typical applications:

We also offer special materials such as:

• Low smoke zero halogen (LSZH) jackets for safety-critical applications

• Fluoropolymer insulations for aerospace and defense

• EMI/EMC braided shields for sensitive data applications

Each material decision impacts cost, performance, and reliability. We optimize for both technical function and wire harness cost optimization.

Real-World Applications

Our wire harness assemblies support:

1. EV Power Systems – high-voltage wiring with EMI protection

2. Medical Devices – miniaturized harnesses with biocompatible insulators

3. Aerospace Modules – lightweight, shielded, vibration-resistant solutions

4. Industrial Machinery – high-flex cables, over-molded for durability

5. Consumer Electronics – compact assemblies with fast connectors

6. Battery Management Systems (BMS) – shielded, high-accuracy signal cables

7. Telecom & Networking – custom cable assemblies for racks and routers

Each industry demands specific certifications and design adaptations. We ensure compliance with wire harness certifications, such as:

• ISO 9001 / IATF 16949

• UL / CE / BIS

• RoHS / REACH

• ISO 6722 / IEC 60228

We also manufacture overmolded cable assemblies in-house, enhancing IP ratings and mechanical endurance.

Testing and Validation Protocols

Our wire harness testing process includes:

1. Continuity Testing – validates connections

2. Hi-Pot Testing – verifies insulation integrity

3. Tensile Testing – checks crimp strength

4. Vibration & Flex Tests – ensures mechanical resilience

5. Thermal Cycling – proves endurance in extreme temperatures

6. Ingress Protection – IP-rated for dust/water sealing

7. Salt Spray Testing – for corrosion resistance (automotive/marine)

8. Microscopic Crimp Cross-section Analysis – confirms crimp geometry

All tests are recorded and archived for traceability, supporting the expectations of wire harness buyers through trust, transparency, and accountability.

Ready to Engineer Your Next-Gen Harness?

Partner with Celestix Industries, your trusted wire harness supplier, to ensure every connection in your system is built for endurance, efficiency, and excellence.

• Request a Quote: https://www.celestixindustries.com/GetaQuote

• Reach Out for Consultation: https://www.celestixindustries.com/contact-us

• Or email us directly at info@celestixindustries.com

Let’s engineer precision together.