Cable and wire harness assembly
Star Precision designs and builds custom cable and wire harnesses, from cutting, stripping and crimping to soldering and final test. Every harness is built to recognized standards and integrates cleanly with your boards and box builds.
Custom harnesses, designed and built
We design and build custom cable and wire harnesses to match your product, then integrate them with your electronics so everything connects the first time.
Each harness runs through cutting, stripping, crimping and soldering, then continuity and automated testing to confirm every connection. We build to IPC/WHMA-A-620 for cable and harness assembly and J-STD-001 for soldering, and we handle both prototype runs and full production. Because our electronics, machining and fabrication teams share the same Houston facility, your harnesses drop straight into a complete box build for customers nationwide.
Real equipment for every step
Each stage of a harness build runs on its own dedicated machine, not a single do-everything station, so cut length, strip depth and crimp force stay consistent from the first unit to the last.
Cutting and stripping
Our Eubanks and Schleuniger cut-and-strip machines handle wire to length, and dedicated jacket strippers handle cable up to 1 in OD, so bulk cable and fine hookup wire both get the right tool.
Crimping and terminating
A universal crimp press handles wire gauges up to 10 AWG, with a dedicated press for ferrule crimping, so terminal pull strength is consistent from the first harness in a run to the last.
Marking and labeling
A hot-stamp marking machine identifies wires and finished harnesses for traceability, so a harness can be matched back to its build record after it ships.
Connector families
Tooled for Molex, Panduit and other standard connector families. Tell us your connector and we will confirm we are tooled for it before you commit to a design.
Harness assembly specifications
Custom design through tested delivery, to the standards your industry expects, backed by dedicated Eubanks and Schleuniger cut-strip machines and a universal crimp press. Bring us a challenging harness and we will tell you exactly how we would build it.
| Build type | Custom design and build |
|---|---|
| Processes | Cutting, stripping, crimping and soldering |
| Wire gauge | Up to 10 AWG on our universal crimp press |
| Jacket stripping | Up to 1 in OD |
| Connector families | Molex, Panduit and other standard families |
| Integration | Integration with your electronics and box builds |
| Testing | Continuity, Hi-Pot and automated testing |
| Volume | Prototype and production runs |
| Standards | IPC/WHMA-A-620 and J-STD-001 |
| Quality | ESD-safe handling |
Our harness assembly process
Every job follows the same controlled path, from design review to final continuity test, so harnesses come off the line accurate, repeatable and ready to integrate whether you order one prototype or a full production run.
- Design and reviewWe work from your drawings, or design the harness with you from a wiring diagram, then quote the complete build.
- Cut and stripOur Eubanks and Schleuniger cut-and-strip machines cut wire to length and strip it precisely for consistent terminations.
- Crimp and solderTerminals are crimped on our universal crimp press or ferrule press, and connections soldered to J-STD-001 requirements.
- Assemble and labelHarnesses are routed, bundled, sleeved and hot-stamp labeled to IPC/WHMA-A-620 for full traceability.
- Continuity testContinuity, Hi-Pot and automated testing verify every pin and connection before the harness leaves the bench.
- Ship or integrateFinished harnesses are packaged and shipped, or integrated straight into your electro-mechanical box build.
Industries we serve
Star Precision builds harnesses for demanding Texas and national manufacturers, including the regulated and technical sectors below, where IPC/WHMA-A-620 certified builds matter as much as the harness itself:
- Electronics, data & telecomWe build harnesses for data and telecom equipment box builds.
- Medical & scientificWe build harnesses for laboratory instruments and medical devices.
- Commercial lightingWe build harnesses that connect driver boards and fixtures.
- Solar & alt energyWe build harnesses for renewable energy mounting and control systems.
What to expect when you work with us
Working with a harness partner should be straightforward. From the first drawing you send to the finished harnesses arriving on your dock, here is what you can count on from our team.
- Send a diagram or a sampleSend drawings, a wiring diagram or a physical harness, and we will build directly from your data.
- Fast, honest quotesWe confirm connector families and wire gauges are ones we are tooled for, then quote fast.
- One point of contactOne team owns your job from cutting through testing and integration, all under one roof.
- NDAs on requestWe sign NDAs on request, so your wiring diagrams stay fully confidential.
- On-time deliveryYou get dependable, on-time delivery from our Texas shop, not an overseas queue.
Cable & Wire Harness Assembly FAQs
Quick answers about our harness services. Company-wide questions are covered in the FAQs at the bottom of the page.
What standards do you build harnesses to?
We build cable and wire harnesses to IPC/WHMA-A-620 for assembly and J-STD-001 for soldering, in an ESD-safe environment.
What processes are involved?
Each harness is cut, stripped, crimped and soldered, then routed, bundled, sleeved and labeled to spec before testing.
Do you test the harnesses?
Yes. Every harness goes through continuity and automated testing to confirm each pin and connection is correct.
Can you integrate harnesses with our electronics?
Yes. We integrate harnesses with your boards and box builds, and because we build those too, the harness is tested against the real product.
Do you handle prototypes and production?
We build both prototype runs and full production quantities, using your design or working with you to develop one.
What connector families are you tooled for?
Molex, Panduit and other standard connector families. Tell us your connector and we will confirm we are tooled for it before you commit to a design.
What is the maximum wire gauge you can crimp?
Up to 10 AWG on our universal crimp press, with a dedicated ferrule crimping press for smaller gauges that need a ferrule terminal.
Can you design a harness, not just build to a print?
Yes. We can design a harness with you from a wiring diagram or a functional description, not only build from a finished print.
Do you only serve customers in the Houston area?
No. We build harnesses from our Northwest Houston facility and ship finished harnesses nationwide. Local customers get the fastest turnaround, but distance is never a barrier.
How do I get a harness quote?
Use the Request a Quote page to share drawings or a sample, or call (713) 983-8883 for a fast, no-obligation quote.
Your turnkey contract manufacturing partner
As a turnkey contract manufacturer, we run metal fabrication, CNC machining and full electronics manufacturing under one roof, so your project never has to leave our hands. From raw material to a tested, finished product, one Star Precision team is accountable for every step, not three different vendors.
A manufacturing partner you can rely on, every time
More than 30 years serving Houston OEMs and Fortune 500 manufacturers with dependable delivery and verifiable quality. Because metal fabrication, machining and electronics all live under one roof, you deal with one accountable team instead of juggling separate vendors.
Our ISO 9001 quality system, IPC and J-STD certified processes are backed by decades of hands-on know-how, and we are as ready to help refine a design as we are to run full production. When another shop is a better fit for a job, we will tell you, because a straight answer is what keeps customers coming back.
About Our QualityDecades of expertise
More than 30 years of fabrication, machining and electronics work for Houston OEMs.
ISO 9001 quality control
Certified for over 25 years, we strive for continuous improvement.
State-of-the-art facilities
115,000 sq ft across two ultra-clean Houston plants, one for metal, one for electronics.
One-stop, turnkey
Metal and electronics in-house with one accountable team, prototype to production.
Streamlinedprocess & on-time delivery.Fast, reliable turnaround times
Fabrication, machining, electronics and assembly all happen in-house, cutting out the vendor-to-vendor handoffs that slow other suppliers down.
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115K+ sq ftacross two facilities.Two state-of-the-art facilities
115,000 sq ft of ultra-clean manufacturing across two Northwest Houston plants, with some of the most advanced fabrication and manufacturing equipment in the industry.
Tour our facility
IPC-A-610certified electronics.Turnkey electro-mechanical assembly
We populate boards, build cable and wire harness assemblies, and integrate them into complete, tested products in an ESD-safe department.
Explore electronicsIndustries we serve
From energy and aerospace to medical instruments and electronics, we build to the standards each industry requires.
Oil, Gas & Energy
Control panels, enclosures and machined parts built for harsh service.
Aerospace & Space
Flight-critical brackets, chassis and precision assemblies.
Defense & Military
Ruggedized enclosures and assemblies built to spec.
Medical & Scientific
Instrument frames and device assemblies with clean finishes.
Electronics & Telecom
Racks, cabinets and complete box builds for data infrastructure.
Industrial & OEM
Frames and sub-assemblies built for equipment makers.
Architectural Metals
Canopies, panels and feature metalwork built to elevate design.
Solar & Alt Energy
Mounting systems and enclosures for renewable installations.
Food Equipment
Stainless machines and food-service equipment, cut, formed and assembled.
Traffic & Infrastructure
Solar signage, beacon enclosures and turnkey roadside assemblies.
Commercial Lighting
Fixture housings, sheet metal enclosures and integrated electronics.
Data Centers
Server rack enclosures, cabinets and cable management for data center infrastructure.
Robotics
Frames, machined parts, control boards and harnesses for robotic equipment.
Automotive
Control boards, sensors, harnesses and housings for automotive electronics.
Consumer Electronics
PCB assembly and box builds for smart home, wearable, audio and IoT products.
Security & Surveillance
Boards, harnesses and enclosures for CCTV, access control and alarm systems.
Agriculture (AgTech)
Sensor boards, controls and rugged enclosures for precision farming.
HVAC & Building Automation
Control boards, panels and harnesses for thermostats and building management.
Retail & Point of Sale
Kiosk enclosures, terminal electronics and complete box builds.
Marine & Maritime
Navigation, communication and monitoring electronics, protected for sea.
Explore our manufacturing case studies
See how manufacturers and engineers rely on Star Precision to take complex projects from concept to finished build, including laboratory instruments, architectural steel and solar traffic systems.
Fraction Collector
A complete laboratory instrument built with every service under our roof, from fabrication and machining to electronics, firmware and final calibration.
Explore all projects
El Paso Airport Art
An 11-gauge steel art canopy laser cut, welded and finished in Sky White, crowned with colorful dichroic acrylic panels.
Explore all projects
Traffic Control Solar Signage
Turnkey solar crosswalk beacons for Carmanah Technologies: sheet metal, full electro-mechanical assembly, programming and testing.
Explore all projects
Corn Tortilla Machine
Fiber laser cut parts at over 4,000 in/min, precision turned rollers, assembled and tested for Tortilla Masters.
Explore all projects
Utility Relay Panel
Custom sheet metal panels reverse-engineered, welded, powder coated and delivered turnkey on pallets for Panelmatic.
Explore all projectsExplore all projects
See every complete build we've delivered, start to finish.
Frequently asked questions
What does Star Precision manufacture?
We are a turnkey contract manufacturer. That means metal fabrication and tube laser cutting, precision CNC machining and Wire EDM, and full electronics manufacturing (PCB assembly, electro-mechanical box build, and cable and wire harness assembly), plus design-for-manufacturability and manufacturing support, all in-house since 1992.
What makes Star Precision a one-stop shop?
Because fabrication, machining and electronics assembly all happen under one roof, we can take a project from raw material and bare board through to a finished, tested and packaged product without handing it off between outside vendors. You get one supplier, one point of contact and one team accountable for the whole build.
Where are you located?
Northwest Houston, Texas, in two facilities. Our Brystone Drive plant (5410 Brystone Drive) houses metal fabrication, and Brittmoore Park Drive (11236 Brittmoore Park Drive) runs machining, electronics and assembly. Both are in Houston, TX 77041.
Are you ISO certified?
Yes. Star Precision is ISO 9001 certified. Our electronics processes are IPC-A-610, IPC/WHMA-A-620 and J-STD-001 certified, with an ESD-safe department, and we use CMM and laser quality inspection for dimensional accuracy.
What materials do you work with?
For fabrication and machining we work in mild steel, stainless steel, aluminum, copper and brass, plus a wide range of electronic components for PCB and electro-mechanical assembly. If you are unsure what suits your part, our team can advise during a design review.
What are your fabrication and machining capabilities?
Sheet metal laser cutting up to 60 x 120 in and up to 1.00 in steel, NC punching and forming on a 220-ton, 14 ft brake, and fiber tube laser cutting of tube up to 30 ft raw and parts up to 236 in. On the machining side we run 5-axis milling, multi-axis turning and Wire EDM, verified by automated CMM inspection.
What electronics assembly do you offer?
SMT, through-hole and mixed-technology PCB assembly, single and double sided, managed by MES software and verified with SPI, AOI, X-ray and functional testing, with conformal coating and potting available. We also build cable and wire harness assemblies and integrate everything into complete electro-mechanical box builds.
Do you handle both prototypes and production?
Yes. We support the full lifecycle, from design-for-manufacturability and prototypes through first article inspection to low and high volume production, so the same partner that helps refine your design can also scale it.
Which industries do you serve?
We build for oil, gas and energy, aerospace and space, defense and military, medical and scientific instruments, electronics, data and telecom, industrial and OEM equipment, architectural metals, food equipment, solar and alternative energy, robotics, automotive, consumer electronics, security and surveillance, agriculture, HVAC and building automation, retail and point of sale, and marine, among others.
How do I request a quote?
Use the Request a Quote page to upload your drawings or CAD files, call us on (713) 983-8883 or email sales@star-precision.com. We review your requirements and reply with a fast, no-obligation quote.