Custom Cable Harnesses – Engineered in Rostock, Manufactured at Our Premium Partner

We work with a wide range of connector systems: Molex, JST, TE Connectivity (AMP), Deutsch (DT, DTM, DTP), Fakra (C, D, L), MATE-N-LOK, Superseal, Hella and many more. We also source customer-specific or rare connector types by arrangement. We engineer your harness in Rostock and manufacture it via our premium partner in China – working with all common automotive and industrial standards.

Our model is built for small series – economical typically from around 500 units. We engineer and plan your harness in Rostock and manufacture it via our long-standing premium partner in China, so you get consistent quality at attractive per-unit cost even as volumes grow. We of course support prototypes and pre-series – just tell us your specific volume.

You receive the concept and quote within about 2–3 working days. We realize the first prototype with our premium partner typically in 2–4 weeks; series and small-series lead times are agreed with you based on scope, components and tooling. For recurring orders we plan material and capacity ahead to minimize lead times.

Ideally a technical drawing or circuit diagram with details on cable types, cross-sections, lengths, connector types and quantities. But a simple sketch or sample cable is also sufficient for an initial calculation. Send us your documents by email or via our contact form.

Yes, Fakra connectors are one of our specialties. We use Fakra C (GPS/GNSS antennas), Fakra D (cellular antennas) and Fakra L (LoRa antennas) in our own GPS tracker products and understand the requirements for RF-compatible cable assembly. The experience from hundreds of our own products flows directly into your orders.

Every cable harness undergoes 100% inspection to our specifications – visual inspection of crimp connections, electrical continuity testing, insulation-resistance measurement where required, and documented final inspection at the manufacturing partner. On request you receive test protocols and traceable serial numbers. Standard-compliant series testing runs in the ISO-9001-certified QMS of our premium partner; acceptance criteria and release are defined in Rostock.

In overmolding, the connector-to-cable transition is molded directly in plastic, creating a one-piece, gap-free assembly with no separate boot or glue. The plastic bonds directly to the cable jacket, distributes mechanical loads over a large area and seals at the same time – eliminating the typical weak point at the connector exit. Compared with a slip-on heat-shrink boot, the result is stronger, tighter (up to IP67/IP68) and more repeatable; heat-shrink remains the cheaper, tool-free choice for prototypes and very low volumes. We design the parting line, material and strain relief in Rostock; the series overmolding is handled by our long-standing premium partner in China.

With gap-free overmolding or potting, protection ratings per IEC 60529 from IP67 (temporary immersion, typically 1 m / 30 min) to IP68 (continuous immersion, e.g. 3 m for 72 h depending on the spec) are achievable – higher and more repeatable than manually fitted O-ring concepts, because no assembly seams remain. We derive the target rating from the application and define material, seals and test criteria. Verification is by spray and dunk testing (pass/fail at zero water ingress), with documented series testing at the certified partner. Note: the stated IP values are partner-validated, not our own certification.

Yes – we use low-pressure molding (hot-melt molding). Instead of the high pressure of conventional injection molding, this process works at only 2–20 bar and low temperature, so SMD parts, fine solder joints and sensors are not damaged. Low-viscosity hot-melt adhesive resins (polyamide/PA, polyolefin/PO or PUR, e.g. Technomelt) solidify in 5–50 seconds and encapsulate the assembly media-tight – faster than two-component potting and with a lower reject rate. This maps directly to our own GPS-tracker and sensor competence: we define material, wall thickness and testing in Rostock, while the low-pressure potting in series is performed by our partner.

We select the cable by application and assemble accordingly: high-temperature (FEP ~200 °C, PFA/PTFE ~260 °C, fiberglass/mica up to ~450 °C, nickel-plated copper above 200 °C), drag-chain/continuous-flex cables (strand class 5/6, PUR/TPE jacket, bend radius from ~5× diameter, millions of bend cycles), marine (tinned copper, XLPE per IEC 60092-351, IP68 glands), halogen-free LSZH (IEC 60754 / 61034 / 60332), CAN bus (twisted pair, 120 Ω) and coax/RF (50 Ω for GNSS/cellular, 75 Ω for video). Thanks to our GPS trackers, coax and RF are genuine core competence from Rostock; compliant series materials and series assembly run via our manufacturing partner.

We define protection per route section. Braided sleeving (expandable PET for flexibility, high-strength nylon for engine bay/heavy-duty) protects against abrasion and heat and spreads open at branches. Taping is done as spiral wrap for flexible sections or half-lapped (~50 %) for higher abrasion and splash protection, with the right tape (PVC, fleece/anti-noise, woven fabric, fiberglass for heat zones). Split convoluted tubing (PA/PP) offers maximum impact and crush protection and is retrofittable, while open spiral wrap bundles in a change-friendly way. Heat-shrink (2:1 to 4:1, adhesive-lined dual-wall) seals splices and connector exits moisture-tight. We inspect abrasion points on the prototype; series runs at the partner.

IPC/WHMA-A-620 is the world's leading workmanship and acceptance standard for cable harnesses, with three quality classes: Class 1 for general products, Class 2 as dedicated service grade and Class 3 for highest reliability (e.g. safety-critical applications). We specify the appropriate class per project and derive the acceptance criteria for crimping, soldering, splices and insulation from it. We test crimp pull-force against the minimum value for the conductor cross-section (AWG); a micro-section additionally shows internal crimp quality (even strand compaction, no voids). We define and provide these criteria; first-article inspection is performed at the premium partner, with assessment and release by us in Rostock. The standard-compliant 100% series testing runs in the partner's ISO-9001-certified QMS.