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Specialist cable assemblies, power distribution, and wiring harnesses engineered for electric vehicles, charging infrastructure, and electrification programmes.
Key engineering and supply chain challenges in this sector — and why specialist knowledge matters.
EV powertrains and charging systems operate at 400V–800V DC. Cable assemblies must meet stringent creepage, clearance, and insulation requirements to protect installers and end users.
Battery packs and inverters generate significant heat. Cables must withstand sustained temperatures of 125°C+ without degradation, requiring careful material selection.
High-frequency switching in inverters and DC-DC converters creates electromagnetic interference. Shielded assemblies are essential to protect CAN bus, LIN, and sensor signals.
EV programmes move fast. OEMs and start-ups need prototype assemblies in days, not months, to hit validation milestones and investor deadlines.
Purpose-built solutions from Circuit Source for this sector.
High-voltage cable assemblies rated to 1,000V DC with appropriate creepage distances, double-insulated conductors, and HVIL (High-Voltage Interlock Loop) integration.
Type 1, Type 2, CCS, and CHAdeMO charging cables manufactured to IEC 62196 and BS EN 61851 standards, with overmoulded strain relief for commercial durability.
Precision wiring for battery management systems — cell voltage sensing, thermistor connections, and current shunt cabling with tight tolerance requirements.
Custom PDUs and busbar assemblies for multi-point charging stations, designed for outdoor IP-rated enclosures with metered output monitoring.
First-off and pre-production assemblies from our UK facility in as little as 7 working days — enabling you to hit DVP milestones without waiting for offshore lead times.
Our engineers review your prototype design for volume manufacturability, identifying cost-saving connector alternatives and assembly optimisations before you scale.
Relevant approvals and quality standards for this sector.
Core capabilities that support this sector.
From rapid 7-day UK builds to cost-effective Far East volume production — engineered to IPC/WHMA-A-620 Class 2 & 3.
View serviceBespoke PDU manufacturing for server racks, data centres, and industrial installations — with intelligent monitoring and control.
View serviceCircuit Source is a trusted custom power supply manufacturer with over 20 years of experience designing and supplying high-quality AC-DC power solutions.
View serviceEnd-to-end management from concept to sea-freight volume — we handle sourcing, manufacturing, logistics, and quality control.
View serviceYes. We manufacture HV assemblies rated up to 1,000V DC with double-insulated conductors, appropriate creepage distances, and HVIL integration. All HV assemblies undergo hipot (dielectric withstand) testing in addition to standard continuity checks.
We manufacture Type 1, Type 2, CCS, and CHAdeMO charging cable assemblies to IEC 62196 and BS EN 61851 standards. We can produce custom lengths with overmoulded connectors for commercial charging networks or fleet installations.
Our UK rapid build service delivers prototype and small batch assemblies in as little as 7 working days. This is particularly valuable for EV start-ups hitting DVP gates or OEMs validating new platforms.
Absolutely. We offer a dual manufacturing model: UK rapid builds for prototyping and pre-production, then cost-effective Far East volume production (4–12 week lead times) using the same specification and quality standards. Our DFM review ensures the design is optimised before scaling.
We offer braided shields, foil shields, and combination shield constructions depending on your EMC requirements. For inverter and motor controller harnesses, we typically recommend 85%+ braid coverage with 360° backshell termination to meet automotive EMC standards.
From first prototype to volume production — get a fast, no-obligation quote from our UK engineering team. No minimum order quantity.
Get an EV Assembly Quote