WIREHARNESSMAKER
English ▾
High voltage wire and cable assembly for new energy vehicles

High Voltage EV Cable Assembly Manufacturer & Supplier

High-Voltage Wire and Cable Assembly Overview

Dongguan Songyuan Technology Co., Ltd. is a manufacturer and supplier of high voltage EV cable assemblies for new energy vehicles, founded in 2017 and operating from an owned 2,000 sqm factory in Dongguan, China. Our high voltage EV cable assembly line is built around two priorities: high-voltage safety that stays compliant and up to date, and vehicle-level durability that holds up in harsh operating conditions. These assemblies route power between battery packs, inverters, and other high-voltage nodes on mainstream EV models, and are produced in our dedicated harness production workshop alongside our drawing/extrusion workshop, quality inspection area, and warehousing and shipping zone.

We serve customers across consumer electronics, industrial control, medical, energy storage, new energy, and hydrogen energy applications, including military-grade cable assemblies. Our team of 60 employees supports roughly 20 million CNY in annual revenue with about 20% average annual sales growth, and we exhibited at NCH2025, the Shanghai International New Energy Connector and Wire Harness Processing Technology Exhibition. Certificates available upon request.

Key Features

Specifications

The following customization dimensions define the build envelope for this high voltage EV cable assembly. Final specifications are confirmed against your vehicle model, power system layout drawing, and interface specifications.

Vehicle & System Compatibility

Compatible with mainstream EV models and matching 30kW~300kW power systems and various battery pack/inverter interfaces. A vehicle model, power system layout drawing, and interface specifications are required to ensure precise compatibility with the vehicle's high-voltage system.

Voltage, Current & Conductor Size

Voltage: DC 600V~2000V. Current: 50A~800A. Conductor size: 6mm²~150mm². A 50mm² conductor is recommended for high-power vehicles above 200kW, and conductor upsizing is required for extra-long distances beyond 8m to reduce power loss.

Material & Protection

Conductor: tinned copper / bare copper / silver-plated copper. Sheath: XLPE / TPU / Teflon. Protection level: IP67~IP68. IP68 protection suits frequent wading scenarios, TPU sheath suits low-temperature regions below -40°C, and Teflon suits severe oil contamination environments.

Connector & Terminal

Connectors: high-voltage sealed / explosion-proof / quick-connect. Terminals: high-voltage crimp / board-to-board. Explosion-proof connectors suit high-voltage systems above 1000V, quick-connect connectors suit frequent maintenance scenarios, and crimp terminals suit bulk assembly.

Integrated Function

Integrate overcurrent fuse / voltage detection module / EMC filter component. Fuse rated current and detection module signal protocol must be specified, and filter components must meet the vehicle's electromagnetic compatibility (EMC) requirements.

Layout & Length

Length: 1m~15m, supporting differentiated lengths for multi-branches. Layout: custom power transmission branches as needed. A vehicle wiring harness layout drawing is required, and branch positions must avoid chassis moving parts to prevent damage from pulling.

Marking & Compliance

Custom vehicle number / voltage level / high-voltage warning / compliance marking. Free laser marking for bulk orders (30 sets or more) with labels such as "High Voltage Danger" or "DC 1000V" to meet vehicle compliance inspection requirements.

Packaging

Individual moisture-proof packaging per set / bulk anti-static packaging / export-customized packaging. Standard delivery uses individual moisture-proof packaging, with anti-static packaging optional for export vehicle matching to prevent transportation damage.

Applications

These high voltage EV cable assemblies are used where power must move safely and reliably at high voltage across a vehicle platform. That includes battery pack and inverter connections, power transmission branches between high-voltage nodes, and other high-voltage runs on mainstream EV models and major EV platforms. The same durability and protection options also suit adjacent programs in energy storage, new energy, and hydrogen energy, where sealed, protected power assemblies are needed in demanding conditions.

If your program involves charging-side wiring rather than internal high-voltage power distribution, see our new energy vehicle AC charging socket wiring harness assembly. For the full range of related builds, visit our new energy vehicle wiring harness category page.

Customization & Ordering

Every high voltage EV cable assembly is built to the vehicle, not to a catalog number. To quote accurately, we ask for your vehicle model, power system layout drawing, interface specifications, and wiring harness layout drawing, along with the voltage, current, conductor size, connector, terminal, protection, and integrated function requirements for your program.

For standard specifications, prototyping is stated at 48 hours. Order quantities are stated as flexible, with prototype runs starting from 100 pcs and volume production from 1,000 pcs. Mass production of assemblies of this type generally takes 15–25 days from order confirmation; the exact schedule is confirmed with each quote. We are an export-oriented supplier serving customers across Southeast Asia, and we can discuss export packaging options for your market.

Talk to an Engineer About Your High Voltage EV Cable Assembly

Whether you are specifying a new high-voltage run, replacing a supplier, or scaling an existing program, our engineering team can review your drawings and recommend conductor, sheath, connector, and protection options that fit your vehicle's high-voltage system.

CTA

For projects that also need vehicle-side charging connection, see our EV charging socket wiring harness.

Certificates available upon request.

Request a Custom QuoteTalk to an Engineer