Production: Shanghai
Warehouse & Sales: Frankfurt
info@mainstar-group.de069 2474 2666-0DEEN
Automotive

Cable harnesses for the automotive industry.

IATF 16949 certified. PPAP documentation, SPC monitoring, Cpk≥1.67 — with up to 40% cost advantage through our own production in China.

Automobil — Wireframe-Illustration
IATF 16949PPAP-Dokumentation, Cpk ≥ 1,67, 0 ppm
Automotive

Series-ready. Documented. IATF 16949.

Automotive customers expect full process documentation, statistical process control and zero-defect quality. Our IATF 16949-certified production delivers exactly that — from batch size 1 to high-volume series.

Bordnetz

Fahrzeugelektrik & Sensorik

Cable harnesses for vehicle electrical system, engine control, driver assistance systems. Defined wire lengths (tolerance ±5mm), shielded lines for CAN/LIN/FlexRay, cross-sections 0.35mm² to 25mm².

ECU

ECU wiring

Precisely assembled wire sets for ECU connections. Contact loading per OEM specification, micro-crimp connections down to 0.13mm² with force-distance monitoring.

HV

E-Mobility & high voltage

High-voltage harnesses for BEV and PHEV. Isolation monitoring, double shielding, orange HV marking per ISO 6469. Cross-sections up to 95mm² for main power circuits.

Automotive-Kompetenz

Your advantage: automotive processes without automotive prices.

IATF 16949 processes, PPAP documentation and SPC monitoring — but with the cost advantages of our own production in Shanghai.

IATF 16949
Certified automotive manufacturing
PPAP Level 3
Full process approval
FMEA
Risikoanalyse vor Serienstart
Cpk ≥1,67
Statistical process capability
Produktbeispiele

From our production.

HV-Kabelsystem E-Mobilität

HV cable system for e-mobility

High-voltage harness (orange) with HV connectors per ISO 6469

ECU-Kabelbaum

ECU Harness

High-pin-count ECU harness with color-coded conductors

Bordnetz-Kabelbaum

On-board Wiring Harness

Complex vehicle harness with textile wrapping and multi-colored conductors

Praxisbeispiel

What we built for an automotive Tier 1.

Case 03 · 2024
DC-Ladekabelbaum für 800-V-EV-Plattform — Wireframe-Illustration
Client · NDACustomer under confidentialitySouthern Germany · Automotive Tier 1

DC charging harness for 800V EV platform

A Tier-1 supplier needed a CCS2 charging harness for its new 800V platform with high-current paths up to 350A — PPAP-documented, IATF 16949-compliant, ramping to 250,000 units/year in 11 months. We delivered a series concept with automated crimping under SPC monitoring and 100% hipot final testing.

Cpk = 1,82(requirement ≥ 1.67)
0 ppmcomplaints at series launch
−38 %unit cost vs. previous supplierUnit cost vs. prior supplier
PPAP Lvl 3approved in 14 weeks
View full case study →/a>
Requirements and metrics are exemplary for this industry.For reasons of contractual confidentiality (NDA), customer name, location and identifying details are not published. Requirements and metrics are exemplary for this industry.

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