Material & Rating
- Connector — high-voltage connector per customer specification or sample, with HVIL option
- Contacts — copper alloy, silver or tin plated, sized to the rated current
- Conductor — stranded or flexible copper, cross-section sized to the current rating on the drawing
- Insulation — XLPE, silicone or TPE selected by voltage and temperature class
- Shielding — braided shield with drain wire, or foil plus braid for EMC-critical runs
- Voltage — rated per drawing - the rating and test voltage are stated on each part drawing
- Temperature — selected by insulation class; stated on the drawing and confirmed in the sample test report
Certification
Cactus Electronics is certified to ISO 9001, IATF 16949 and UL and manufactures to the IPC/WHMA-A-620 workmanship standard. Raw materials comply with RoHS. Every assembly passes 100 % electrical testing - continuity, insulation resistance and withstand voltage - before packing, and the QC-to-production personnel ratio is 1:3.
Application
High-voltage assemblies are used everywhere power moves between the pack, the inverter and the loads of an electric vehicle.
- Battery pack to inverter and DC-DC converter links
- Traction motor three-phase connections
- On-board charger and DC fast-charge inlet wiring
- Battery pack internal interconnect and service plugs
- Electric bus, truck and special vehicle powertrains
- Industrial and energy storage battery connections
Custom Options
- Conductor cross-section, voltage class and current rating per drawing
- Insulation: XLPE, silicone or TPE, single or double wall
- Shielding: braid, foil plus braid, or unshielded
- Connector interface: per specified supplier part, or supplied as a complete overmolded assembly
- Samples in 3–7 working days; MOQ confirmed per project
- Customer carton marking and DDP delivery on request
FAQ
What is the operating temperature rating of this harness?
Standard PVC-insulated assemblies are rated to 80 °C; XLPE or TPE insulation raises the rating to 105 °C. High-voltage builds use XLPE or silicone insulation selected for the temperature class on the drawing, and every part is hipot tested at the voltage stated on that drawing. The exact operating range for a part number is stated on its drawing and confirmed in the sample test report.
Is this overmolded harness waterproof?
High-voltage assemblies are overmolded at the connector, so a mated pair is sealed against water and dust; the ingress protection level is specified on the drawing and verified on the sample. The ingress protection level (typically IP67 for a mated pair) is specified on the drawing and verified during sample validation. Non-overmolded assemblies can be supplied with heat-shrink or grommet sealing instead.
Can I customize the pinout and connector type?
Yes. Pinout, connector series and gender, cable length, wire gauge, jacket colour and overmold shape are all customer-defined. Voltage class, conductor cross-section, shielding and connector interface are all built to your drawing or sample. Send a drawing, a sample, or a pinout table and we return a 2D/3D drawing prepared to IPC/WHMA-A-620 for approval before tooling.
What is your MOQ for custom cable?
MOQ is confirmed per project and depends on harness complexity, connector cost and tooling. Prototype and pilot batches are accepted before mass production, so a new programme can start with sample quantities. Samples are produced in 3–7 working days and mass production runs 20–30 days after approval.
What testing standards do you apply for harness?
Production follows IPC/WHMA-A-620. Every assembly is 100 % electrically tested for continuity, insulation resistance and withstand voltage; the in-house lab adds temperature and humidity cycling, salt spray, connector insertion and withdrawal force, and cable bending tests. Inspection records are kept in the ERP system.
