Multi-station harness forming board supporting parallel prototype and production builds

Wire Harness Prototyping & New Product Introduction

Linkssor builds prototype wire harnesses in 5–7 working days from an approved drawing or sample, including connector sourcing, crimp validation and 100% electrical testing. Approved prototypes then transfer to volume production on the same process settings, with first-article inspection and traceability documented at both stages.

A prototype that cannot be reproduced in volume is a demonstration, not a sample. We build prototypes on the same equipment and the same process settings that will be used in production, so the approval you give is meaningful.

Parallel station builds during prototype stage

Bench assembly of a conduit-covered prototype harness

Prototype to volume — what happens at each stage

Stage	Typical lead time	What happens
Prototype / A-sample	5–7 working days	Built from approved drawing, sample measurement or specification. Connector sourcing, crimp validation and 100% electrical test. Delivered with a dimensional and test record.
Engineering sample / B-sample	7–12 working days	Design changes from the A-sample evaluation incorporated. Crimp micro-section analysis added. Full inspection report issued.
Pre-production / C-sample	12–18 working days	Built on production equipment with production fixtures. Process capability checked. Documentation package issued for your approval.
Volume / SOP	Per schedule	Transferred to volume lines with locked process settings, lot traceability and the inspection regime agreed at C-sample.

Documentation issued with prototype and pre-production builds

Dimensional inspection report against the approved drawing
Crimp height and pull-out force record per terminal type
Crimp cross-section micro-analysis image
Electrical test record — continuity, pin-out, HIPOT where specified
Material and component declaration with identified part numbers
Certificate of conformity referencing the applicable standard

Where our volume sweet spot sits

Stage	Order volume
Prototype / A-sample	1 – 50 units
Engineering & pre-production	50 – 500 units
Low-to-mid volume production	500 – 5,000 units / month
High volume on dedicated line	5,000 – 30,000 units / month

Our capacity is 100,000 harness sets per month across eight assembly lines. Programme fit is best for prototype and low-to-mid volume builds, launch-phase supply and aftermarket or service-part runs. High-volume programmes are welcome where they are supported by a dedicated line and a scheduled call-off.

FAQ

What is the real sample lead time?

5–7 working days for a typical harness where connectors are in stock. Where a connector must be sourced from overseas distribution, add the transit time — we will state it in the quotation rather than absorb it silently.

Can you build A and B variants in parallel?

Yes. Parallel sample builds are standard where your validation plan requires a comparison, and they share the tooling and forming board.

Do you charge for tooling?

Forming boards and test fixtures are quoted as tooling where they are part-specific. Simple fixturing is often absorbed into the piece price.

What happens between C-sample approval and volume?

Process settings are locked, the forming board and test fixture are released to the line, and the inspection regime agreed at C-sample becomes the production control plan.

Build to Drawing

Build to drawing means Linkssor manufactures strictly to the design record you supply — drawing, BOM and specification. We return a DFM review before.

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