EV Charging Cable & Harness Solutions for Every Charging Architecture
Custom cable assemblies, internal wiring harnesses, and connector solutions engineered for AC wallboxes, DC fast chargers, charging stations, portable EVSE units, and battery-energy-storage interfaces — built to match your charger structure, current rating, and installation environment.
See Where Our Cables Fit Into Your Charging Equipment
From the charging gun to the internal power loop, every cable and harness has a defined role. Use the map below to identify which assemblies match your charger architecture — so design discussions start with the right reference, not a generic catalogue.
Not sure which cables your project needs? Share your charger structure and our engineers will map it for you.
Map My Charger Architecture →What Can Go Wrong in EV Charging Cable Projects?
Small cable issues create large charging-equipment failures — failed homologation, field returns, and missed launch windows. We help you spot the risks early, before tooling and mass production lock them in.
Risk 01
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Cable & Harness Solutions Matched to Your Charger
Different charging architectures impose very different cable requirements. Pick your equipment type below to see exactly which cable, harness, and connector solutions fit — and why.
Compact Internal Harnesses With Clean, Repeatable Routing
Wall-mounted units leave little room inside the enclosure. We build harnesses sized to your cabinet drawing, with branch points and tie-down positions matched to your PCB and contactor layout — so every unit looks the same on the production line.
- Compact harnesses pre-formed to your enclosure dimensions
- Stable signal transmission for CP, PP, and metering lines
- Charging-gun cable options in Type 1, Type 2, and GB/T
- Color-coded, labeled branches for fast assembly-line handling
High-Current Cable Assemblies Built for Continuous Load
DC fast-charging cabinets push the cable spec hard — high current, sustained sessions, tight bend radii. We size conductors with thermal margin, use temperature-resistant insulation, and pair them with high-reliability terminals so the assembly behaves the same on day 1 and day 1,000.
- Heavy-gauge DC cables with thermal margin for sustained sessions
- Temperature-resistant insulation suited to cabinet hot-spots
- Reliable, traceable terminals with documented crimp parameters
- Liquid-cooled cable interface options for high-power gun assemblies
Waterproof Outdoor Connections Built to Outlast the Weather
Roadside and forecourt installations face rain, dust, UV, and field service crews. We focus on properly specified sealing, strain relief, and serviceable connector zones — so a five-year deployment doesn't become a five-year warranty exposure.
- IP67 / IP68 sealed connector areas with verified gland selection
- UV- and ozone-resistant jacketing for outdoor cable runs
- Long-term durability under thermal cycling and field vibration
- Service-friendly layout for on-site maintenance access
Flexible, Durable Cables That Survive Daily Coil-and-Uncoil
Portable units live in trunks, get dropped, dragged, and coiled around hands. Cable construction matters more here than almost anywhere else — flexibility, abrasion resistance, and plug-end strain relief decide whether a unit lasts one year or five.
- High-flex cable construction rated for repeated coiling cycles
- Abrasion- and oil-resistant jacketing for real-world handling
- Reinforced strain relief at both plug and control-box ends
- Travel-friendly cable diameter without compromising current rating
Stable Power & Signal Links Between Chargers and Batteries
When a charger sits next to a battery cabinet, cable behavior decides system uptime. We build power and signal assemblies sized for the storage architecture — with shielding, length-matched runs, and labeling that survives the install crew.
- High-current DC links between charger output and storage cabinet
- Shielded, length-controlled signal harnesses for BMS communication
- Insulation systems rated for continuous bidirectional load
- Color, label, and routing schemes aligned to your system drawing
From Charger Design to Cable Solution — Before the First Sample Ships
Share your charger structure, current rating, connector requirement, and installation environment. Our engineering team reviews cable routing, connector matching, insulation, and assembly feasibility together with your team — so the first sample arrives close to production-ready, not three revisions away.
Send a drawing, a sample, or even a rough sketch — our engineers will respond with a cable & connector review within 24 hours.
Start an Engineering Review →Match Your Procurement Need to a Concrete Cable Solution
Procurement and engineering teams describe needs in different language. The matrix below translates the typical EV-charging project requirement into the specific cable, connector, or harness solution that addresses it — so quoting starts with substance, not slogans.
Have a need that doesn't fit a single row? Most projects don't — we'll build the matrix around your spec.
Build My Custom Solution →Tested for Charging-Equipment Reliability
Every custom assembly can be supported with inspection records and reliability-test reports scoped to your project requirements — so the cable inside your charger has a paper trail, not just a promise.
Traceability Pack
- Final test record (FTR) Per Lot
- Material certificate (CoC) Per Batch
- Crimp data & pull-force log Sampled
- Hi-pot / IR test report Per Project
- Visual inspection summary Per Order
Need a specific test added to your project's validation plan? Tell us the standard, the sample size, and the report format you need.
Define My Validation Scope →Documentation Support for Global EV Charging Projects
From sample approval to final shipment inspection, EV charging programs in North America and Europe demand a documentation trail that holds up under audit. Open any folder below to see what we can package with your project.
Quality Management Certifications
ISO 9001 · IATF 16949 · ISO 13485
- ISO 9001 — general quality-management system foundation
- IATF 16949 — automotive-grade process discipline applicable to EV programs
- ISO 13485 — controlled processes when assemblies overlap with medical devices
Product & Material Compliance
UL · RoHS · REACH
- UL component recognition for cables and connectors used in North American projects
- RoHS declarations confirming restricted-substance limits for EU shipments
- REACH substance disclosure for high-volume customers requiring SVHC visibility
Process & Workmanship
IPC/WHMA-A-620 Capability
- IPC/WHMA-A-620 — workmanship standard for cable and harness assemblies
- Trained operators and documented work instructions aligned to the standard
- Visual acceptance criteria attached to inspection records on request
Material Data Documentation
CoC · MDS · Datasheets
- Certificate of Conformance (CoC) issued per shipment lot
- Material Data Sheets for wire, insulation, and connector components
- Supplier-traceable references for change-controlled bill of materials
Inspection & Test Reports
FTR · Hi-Pot · IR · Pull-Force
- Final Test Reports (FTR) with pass/fail data per lot
- Hi-pot and insulation-resistance summaries scoped to project specification
- Pull-force and crimp-quality logs available on request
Export-Ready Project Packs
EU · UK · NA · APAC
- Region-specific documentation bundles for customs and incoming inspection
- Packing list, commercial invoice, and conformance statements aligned to the destination
- Project-level audit trail prepared in advance of supplier reviews
How Real EV Charging Projects Get Solved
Three short scenarios — typical of the customer projects we support — showing how a defined cable or connector problem turns into a deployable solution. Use them to identify which scenario looks most like yours.
EV Charger OEM
Compact Internal Harness for a New AC Wallbox
Station Integrator
Waterproof Outdoor Connector for a Roadside Station
ESS + Charging
Stable Power & Signal Links for a Storage-Coupled Charger
If one of these scenarios looks close to your project, the fastest next step is a 24-hour engineering review of your spec.
Talk to an EV Cable Engineer →Get Engineering Feedback on Your Cable & Connector Spec
Send us your drawing, sample, or project specification. Our team will review the cable and connector solution for your EV charging application — and come back with an engineering response, not a generic data sheet.
- Drawings and samples stay confidential under NDA on request
- IPC/WHMA-A-620-aligned workmanship and traceable production
- Support for AC, DC fast, portable, station, and ESS-coupled chargers
- Documentation packages built for EU, UK, NA, and APAC shipments