Every assembly tested before it ships.
Inspection and testing happen at our manufacturing partner as part of the build. Continuity is checked on every unit; hi-pot, insulation resistance and pull-force follow the plan agreed in your quotation, and the records that plan calls for ship with the lot.
From the first reel to the packed lot
Wire harness testing is not one step at the end. A cable assembly or wire harness is checked from the day its material arrives to the day it ships, at the manufacturing partner, under a plan written into your quotation.
- 01Incoming material inspectionWire, connectors and terminals are checked against the bill of materials when they arrive. The brands and part numbers are the ones confirmed in writing, so a substitution cannot slip in at the bench.
- 02First articleThe first unit of a new build, or of a new revision, is built and checked against the drawing before the run starts, and you approve it.
- 03In-process inspectionWork follows controlled instructions, and crimp height is monitored as terminals are crimped, so a drifting tool is caught during the run rather than at the end of it.
- 04Final electrical testEvery finished unit is tested for continuity: each circuit on the right pin, no opens, no shorts. Hi-pot and insulation resistance are added when the drawing or the agreed plan calls for them. A unit that fails is set aside and handled as a nonconformance.
- 05Visual inspection and final QAWorkmanship is checked to the IPC/WHMA-A-620 class agreed for the project, and labels and color coding are checked against the drawing.
- 06Packing and recordsAssemblies are packed and labeled to the order, each lot stays traceable, and the records agreed in the quotation leave with it.
What can be tested, and when
The cable assembly testing available for your build, from the harness continuity test every unit gets to hi-pot testing where the specification calls for it. No test voltage or cycle count is published here: each comes from your drawing or from the plan agreed in the quotation.
Continuity, open, short and miswire
Each conductor lands on the pin the drawing says, with no open circuit and no short between circuits. On keyed and sense connectors this is also the pin-to-pin mapping check.
Hi-pot (dielectric withstand)
The insulation holds a test voltage above the working voltage without breaking down. Voltage and duration come from your specification or the agreed plan; neither is assumed.
Insulation resistance
Leakage between conductors, and from a conductor to the shield or to ground, stays above the limit your specification sets.
Crimp pull-force
A terminated wire holds the force expected for its gauge and terminal before it pulls out or breaks. Results come back with the samples, and are kept per lot where the plan says so.
Crimp cross-section
A micrograph of the cut crimp: strand compaction, bell mouth and insulation grip, the things a pull test cannot show. Connector assembly →
Crimp-height monitoring
Crimp height measured during the run against the terminal maker’s figure, so a worn or misadjusted applicator is caught early.
Flex-life cycle test
For a cable that bends or twists in service: the chosen construction runs on the manufacturing partner’s cycle-test rig, moved the way your machine moves it. The target, the pass criterion and the report are set per project, and the target is agreed for that test rather than published as a promise. High-flex cable assembly →
Custom test fixtures
A fixture built for your assembly when a standard tester cannot reach every circuit, or when you want the test run the way your own procedure describes.
Technical detailConnector assembly →High-flex cable assembly →High-current DC assembly →Build-to-print manufacturing →
What ships with the lot
The paperwork follows the plan: what was agreed in the quotation is what arrives with the parts, and nothing is invented after the fact.
Test report
A test report can accompany every order. Which tests it covers and how it is laid out are set in the quotation, so the report you receive matches the plan you agreed.
Certificate of conformance
A COC for the lot, on request, stating that it was built and tested to the drawing revision on the order.
Inspection records and micrographs
First-article and in-process inspection records, and crimp cross-section micrographs, when the plan includes them.
Traceability
Lots are traceable, so a question about a shipment later on can be tied to the records kept for that lot.
What our manufacturing partner works to
These are our manufacturing partner’s. Interconnix holds no certification of its own and claims none; the partner’s certificates can be sent with a quotation. A certificate covers the quality system, not a particular assembly: what proves yours is the test plan and the records that come with it.
A plant visit or a video audit can be arranged with the partner.
- ISO 9001 — held by the manufacturing partner
- IPC/WHMA-A-620 workmanship, class agreed per project
- UL/AWM wire available
- RoHS and REACH materials on request
- COC on request
- Connector brands confirmed in writing
The same plan, in six applications
Every industry gets the same discipline; what changes is which tests the plan leans on. Six examples, each on its own page with the rest of the requirements.
Robotic cable assemblies bend and twist on every cycle: continuity on every unit, hi-pot and pull-force per plan, and flex life run on the cycle-test rig at the joint’s own motion.
Industry page →AI hardwarePower and data looms for computeAI server cable assemblies: short high-current jumpers between boards and busbars, lengths matched and recorded, continuity on every unit, hi-pot per plan.
Industry page →Data centers & networkingRack and chassis cablingBuilt assemblies are tested for continuity to the agreed plan; sourced interconnects ship as their manufacturer supplies them, with the part number confirmed.
Industry page →Medical equipmentDevice and cart harnessesContinuity on every unit and hi-pot per plan, pull-force results kept per lot, and the scope and format of the records agreed before the order.
Industry page →Energy storageBattery sense and power leadsPin-to-cell mapping of every sense harness checked before it ships, lugs crimped and pull-tested, insulation rated to the system voltage and hi-pot per plan.
Industry page →Test & measurementInstrument and fixture cablingContinuity on every unit, with hi-pot and insulation resistance per plan, because a leaky cable shows up as a measurement error nobody can find.
Industry page →What to put in your RFQ
Put it in the drawing or the RFQ and it goes into the quotation and the plan. Left out, continuity on every unit still applies, and the rest is agreed with the quotation.
- The tests you require, and whether each applies to every unit or to a sample
- Hi-pot and insulation-resistance levels and durations from your specification, where they apply
- Pull-force minimums per terminal and wire size, or the standard to apply
- The IPC/WHMA-A-620 class, if your drawing calls one out
- The records you want with the lot: test report, COC, micrographs, inspection records, and their format
- For a cable that moves: how it bends or twists, how often, and the cycle target to test to
Common questions about testing
Is every cable assembly tested before it ships?
Every unit gets a continuity test: each conductor on the right pin, no opens, no shorts. Hi-pot, insulation resistance, pull-force and anything else follow the plan agreed in the quotation, which is written from your drawing and your specification.
Do you hi-pot test every assembly?
When the drawing or the agreed plan calls for it, yes, at the voltage and duration your specification sets. It is not applied to every build by default, because the right level depends on the product, so it is confirmed in the quotation rather than assumed.
Can a test report come with each shipment?
Yes. A test report can accompany every order; its scope and format are set in the quotation. A certificate of conformance, inspection records and crimp micrographs can be added when the plan includes them.
Is Interconnix ISO 9001 certified?
No. The manufacturing partner that builds the assemblies holds ISO 9001; Interconnix holds no certification and claims none. The partner’s certificate can be sent with a quotation. A quality-system certificate speaks for the system, not for any one product, which is what the test plan is for.
Can you test to our own procedure or fixture?
Usually, yes. Send the procedure or the fixture drawing with the RFQ; the partner confirms what its line can run, a custom fixture is built where one is needed, and the agreed method goes into the quotation.
Can we visit or audit the plant?
A visit or a video audit can be arranged with the manufacturing partner. Ask when you send the RFQ or place the order, and we coordinate it.
Send the drawing and the tests it calls for.
Attach the drawing or the specification, say which tests and records you need, and the quotation comes back with the plan written in.