Wiring harness manufacturing: harnesses made to measure
Wiring harnesses that fit at the first installation.
- assembly to drawing
- Assembly board
- electrical final testing
- 100 %
- to series
- Single piece
Overview
Wiring harnesses that fit at the first installation.
A wiring harness bundles cables, contacts, connectors and protection into a single part with a fixed geometry. Powertune manufactures wiring harnesses for vehicles, machines and systems, from the single piece to series production, in our own plant in Kitzingen.
The basis is your drawing, bill of materials, 3D data or a sample, or a design from our own CAD design office working with EPLAN. Every wiring harness is built on the assembly board and tested electrically.
Scope of services
Wiring harness manufacturing at Powertune: what is included.
- Wiring harnesses to drawing, sample or 3D data
- Built on the assembly board with branches and distributors
- Taping, bundling and protection with corrugated tube, braided sleeve or heat shrink tubing
- Ultrasonic splices and twisted cables
- Marking of cables and branches
- Electrical final testing with a test report
A wiring harness is only finished once it has been tested. That is why every wiring harness goes through the electrical final test.
Examples
From our production.
Structure
What makes up a wiring harness.
A wiring harness connects many components through a single part: cables of different cross sections, contacts and connectors, electrical nodes, branches with fixed dimensions, protective tubing, fastenings and clear marking. Its geometry is defined in a drawing and reproduced one to one on the assembly board.
For it to fit at the customer without rework, the lengths, branch points, pin assignment and protection have to be right, on every single piece.
- Cables and strands in matching cross sections
- Crimp contacts, connectors and single wire seals
- Ultrasonic splices and twisted cables
- Corrugated tube, braided sleeve or heat shrink tubing and adhesive tape as protection
- Marking of cables and branches
Manufacturing
How a wiring harness is built at Powertune.
Assembly takes place on modular assembly boards. The holders are not fixed, they are repositioned for the next wiring harness. There is no need to build a separate board for every order, and the set-up time between two orders stays short. This pays off especially with large wiring harnesses and repeat orders.
The template for this is printed on our own plotter in A0 format. The wiring harness is built at a scale of 1:1 on this drawing: lengths, branch points and connector positions are taken directly from it, not measured again. This keeps the build true to size, and the second batch is built exactly like the first.
- Design work or adoption of your drawing, assembly board set up to size
- Cable processing on fully automatic and semi-automatic machines: cutting to length, stripping, seal, crimping
- Pre-assembly: ultrasonic splices, twisted cables, soldering and tinning
- Building on the modular assembly board, at a scale of 1:1 on the plotted drawing: routing the cables, setting the branches, fitting the connectors
- Taping and bundling with the KABATEC KTHB Smart and the KTB 50-E plus, cutting protective tubing to length
- Electrical final testing, marking, documentation and packaging
Every step takes place in our own plant in Kitzingen. Short distances between design, cable processing and assembly make samples fast and changes manageable.
Quality
What matters with wiring harnesses.
Most problems with wiring harnesses do not arise on the individual cable but at its transitions: at swapped pins, at branches that are too short, at chafing points without protection or at leaking connectors. That is why we do not rely on spot checks: we test every single wiring harness electrically.
Processing is documented without gaps, from the individual cable to the finished wiring harness. You will find details on the scope of testing and the records under Testing & documentation.
FAQ
Frequently asked questions.
What is a wiring harness?
A wiring harness is the structured bundling of several cables with contacts, connectors, branches and protection into a ready to install part. It connects control units, sensors, actuators and loads and handles the power supply and the signal transmission.
How does a wiring harness differ from a cable set?
A cable set consists of several assembled cables for one application that are not necessarily connected to each other. A wiring harness is a bundled part with fixed branch dimensions that is built on the assembly board and installed as a whole.
Can you rebuild a wiring harness from a sample?
Yes. We manufacture wiring harnesses to a drawing, a bill of materials, 3D data or from an existing sample, and we prepare the production documents from it. This is how we also reconstruct wiring harnesses for classic cars such as the VW Golf 1.
Do you also take on the design of the wiring harness?
Yes. Our CAD design office has worked with EPLAN since 2023 and develops complete cable systems to customer order, from the cable routing in the 3D model to the 2D production drawing with a bill of materials. More on this under Development & design.
How are wiring harnesses tested?
Every wiring harness goes through an electrical final test for continuity and short circuits; our test system records the pin assignment, the resistance and wiring faults and logs the results. We carry out high voltage and functional tests as required.
Which quantities are possible?
From the single piece through samples and pre-series to series production. Since 2006 Powertune has manufactured 950,000 wiring harnesses (company figure, as of July 2026).
What is a modular assembly board?
An assembly board, also known in the industry as a nail board or form board, carries the drawing of the wiring harness at full size. Holders and pins define the routing, the branches and the connector positions, so that every wiring harness gets the same dimensions. Modular means that the holders are not fixed but are repositioned for the next wiring harness. A separate board therefore does not have to be built for every order, which saves set-up time. The template is printed on our own plotter in A0 format, and the harness is built on it at a scale of 1:1.
Request a quote
Let us talk about your project.
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will get back to you with a non-binding quote.
More services
Everything from a single source.
Cable assemblyReady to install cables, cable sets and wiring harnesses
Development & designCAD design with EPLAN, documentation to PPAP
PrototypingSamples, single pieces and pre-series
Series productionFully automatic cable processing machines, MES controlled and traceable
Testing & documentationProcess monitoring, electrical final testing, test recordsIndustry solutionsTo the overview