sensor parts wiring assembly

Sensor Wiring Assembly Solution

Integrated cable, connector, overmolding and sensor component manufacturing for automotive and industrial applications — from prototype to mass production.

Discuss Your Application

Wiring Assembly

E-Tech Solutions

We manufacture custom wiring harnesses for sensor systems, covering terminal crimping, cable processing, and connector integration. All products are produced under controlled processes with electrical testing and quality verification to ensure reliable performance in harsh environments.

sensor parts wiring assembly

What We Build

Complete Sensor Assembly Manufacturing

E-Tech provides integrated manufacturing solutions — combining cable processing, connector assembly, injection molding, overmolding, metal components and testing in one facility.

Cable Processing
Cable Assembly
Injection Molding
Overmolding
Metal Components
Testing & Validation
Connector Housing

Injection Molding

Connector Housing
  • PA66 GF / PPS / LCP
  • IP67 / IP68 rated designs
  • Custom cavity configurations
  • Insert molding available
Terminal & Contact Parts

Metal Stamping

Terminal & Contact Parts
  • Copper / Phosphor Bronze / Brass
  • Gold / Tin / Nickel plating
  • Auto crimping ±0.05mm
  • Pull force 100% tested
Overmolding & Seal

Overmolding

Overmolding & Seal
  • TPU / TPE / Silicone
  • IP67 / IP68 protection
  • Custom strain relief design
  • Vibration & flex durability
Cable & Harness

Cable Processing

Cable & Harness
  • Automated cut / strip / crimp
  • Multi-core harness assembly
  • Length tolerance ±1mm
  • 100% continuity test
Complete Sensor Assembly

Sub-Assembly

Complete Sensor Assembly
  • Cable + connector + overmold
  • Sensor interface integration
  • 100% electrical testing
  • Customer labeling & packaging
Metal Bracket & Support

Metal Forming

Metal Bracket & Support
  • SPCC / SUS304 / Aluminium
  • Stamping + bending + forming
  • Zinc / nickel plating
  • Cable routing & strain relief

Why E-Tech

Capability Built For Sensor Applications

Six engineering strengths that differentiate E-Tech from a standard wiring house.

Precision Cable Processing
Automatic cutting, stripping and crimping with ±0.05mm terminal position accuracy. Process-controlled for stable electrical performance across high volumes.
Connector Integration
Terminal assembly and connector integration supporting custom sensor applications. In-house injection-molded housings eliminate third-party tooling dependency.
Overmolding Capability
TPU / TPE overmolding solutions for IP67 / IP68 rated assemblies. Integrated seal design developed with DFM review — no outsourced tooling delay.
Electrical Validation
100% continuity, insulation resistance and pull-force testing before shipment. Test data archived per lot — available for customer audit and PPAP submission.
Custom Engineering Support
DFM review, prototype development and production optimisation. Our engineering team responds to RFQ within 3–5 working days with DFM feedback included.
Automotive Quality System
IATF 16949 certified. Full PPAP, APQP and FMEA support for automotive Tier 1 and OEM customers. Customer-specific requirements built into the control plan.

Cable & Material Capability

Material Matched to Your Environment

We select and stock the cable grades that sensor and automotive environments actually demand — not catalogue defaults.

sensor parts wiring assembly
PVC

−40°C to +105°C

  • Cost-Effective
  • Good Flexibility
  • General Indoor Use
TPE

−40°C to +125°C

  • Oil resistant
  • High flexibility
  • Automotive grade
PUR

−40°C to +80°C

  • Abrasion resistant
  • Chemical resistant
  • Industrial / robotic
Silicone

−60°C to +180°C

  • High temperature
  • Flame retardant
  • Engine bay ready
Custom Specification Support
Voltage Rating
From signal level to 600V power cable — specify your system voltage
Temperature range
We match insulation material to your operating and peak temperature requirement
Waterproof rating
IP67 / IP68 available through overmolding and seal design — confirmed by immersion test
Durability & flex life
Flex cycle tested per UL or IEC standard — PUR and TPE recommended for moving applications
Chemical resistance
Oil, fuel, coolant — we specify the correct jacket material for underhood environments

Integrated Manufacturing

One Partner From Metal To Assembly

E-Tech combines metal forming, plastic molding and assembly capabilities to reduce supplier complexity and improve project efficiency.

Submit your drawing, specification or requirement brief. Our engineering team reviews cable spec, connector type, IP rating, temperature range and production volume. We issue DFM feedback and preliminary quote within 3–5 working days.
Engineering review of connector design, cable routing, seal geometry and overmolding parting line. DFM report covers: bend radius, connector clearance, overmold wall thickness, tooling feasibility. Changes agreed before prototype order.
Automated cut, strip and crimp on Komax or equivalent equipment. Length tolerance ±1mm. Terminal position accuracy ±0.05mm. Pull force tested on every reel change. Process parameters logged per job.
Terminal insertion into connector housing verified by insertion force monitoring. Correct seating confirmed by touch probe. Connector coding / keying verified against assembly drawing. 100% verified before overmolding.
TPU, TPE or silicone overmolding on in-house injection presses. Gate location, shot weight and cooling time documented and locked in production record. Each cavity produces a consistent seal geometry — confirmed by first-off dimensional check.
100% electrical continuity (open, short, miswire). Pull force test per terminal specification. Insulation resistance at 500V / 1000V DC. IP67 or IP68 immersion test on defined sample. Test data archived per lot number.
Start of production (SOP) with active SPC on critical dimensions, 100% electrical test, and AOI visual inspection. Control plan, FMEA and reaction plan in place. Lot traceability from raw cable to finished assembly.

Applications

Applications we support

Sensor cable assemblies across automotive powertrain, industrial equipment and EV systems.

temperature sensor assembly
Temperature Sensor

High-temp TPE/Silicone cable. Overmolded connector. Engine bay rated.

pressure sensor assembly
Pressure Sensor

IP67 rated. Custom connector housing. Oil/chemical resistant jacket.

wheel speed sensor assembly
Wheel Speed Sensor

Flex-rated PUR cable. High-cycle durability. ABS system compatible.

lambda sensor assembly
NOx / Lambda Sensor

Exhaust environment rated. Silicone insulation. Heat sleeve included.

position sensor assembly
Position Sensor

Shielded cable. Low EMI. Precision terminal crimping.

vibration sensor assembly
Knock & Vibration Sensor

Engine bay flex routing. Strain-relief overmolding. 100% electrical test.

Testing & Validation

Quality Proven Before Shipment

Every assembly goes through a defined test sequence. Test data archived per lot and available for customer audit.

100% Electrical Continuity
Every wire path verified. Open, short and miswire detected before assembly leaves the line.
Pull Force Test
Terminal pull-out force verified per IEC or UL standard. Values documented on first article report.
Insulation Resistance
High-voltage insulation test at 500V DC / 1000V DC depending on specification. Pass/fail per IEC 60228.
Waterproof Test (IP67/68)
Immersion test at 1m / 30 min (IP67) or 3m / 30 min (IP68). Leak check and post-immersion electrical verification.
Thermal Cycling
−40°C to +125°C thermal shock cycling per USCAR-2 or customer-specified standard. Electrical verified after test.
PPAP & First Article
Full PPAP documentation including dimensional report, MSA, SPC and PSW — AIAG Level 2/3 and VDA 2 compliant.
sensor parts wiring assembly
sensor parts wiring assembly

Project Examples

Delivered to production

Representative cases from sensor cable assembly projects. Detail available under NDA.

sensor parts wiring assembly
Automotive · Temperature Sensor
Automotive Temperature Sensor Harness

Silicone cable

TPE overmolding

Mass production

Challenge

High temperature environment up to 150°C. IP67 seal required. Assembly integration with injection-molded sensor housing.

Solution

Silicone cable + TPE overmolded connector. Seal and housing co-developed in-house. 100% electrical + immersion test before shipment.

sensor parts wiring assembly
Industrial · Pressure Sensor
Industrial Pressure Sensor Cable Assembly

PUR cable

IP68

Mass production

Challenge

Chemical and oil resistance needed. IP68 rating in hydraulic system. Flex life >500,000 cycles in articulating machine arm.

Solution

PUR flex cable with chemical-resistant jacket. IP68 overmolded M12 connector. Flex cycle verified before SOP approval.

sensor parts wiring assembly
EV · Battery System
EV Battery Temperature Sensor Harness

FR cable

Multi-zone NTC

Mass production

Challenge

12-zone NTC temperature array in battery pack. Flame-retardant requirement (UL 94 V-0). Space-constrained routing in BMS housing.

Solution

Custom multi-branch harness design. FR silicone cable. Connector housing injection-molded in-house. Complete sub-assembly delivered.

Get a Quote

Tell Us About Your Part

Talk to an engineer, not a chatbot

Send your requirements and a real application engineer will respond within one business day with feedback and pricing.

E-mail:
rita@e-techdz.com
Tel:
+86 15220055290
Address:
No. 101/102, W3 Bldg, Tian’an Shenchuanggu, 178 Dongshen Road, Dongguan 523690, Guangdong523000
Response Time:
Within 1 Business Day
Export Experience:
30+ Countries Served
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