Since 2000 · 3,000+ customers

Manufacturing · India · Mahadevapura, Bengaluru

Cable harness manufacturer in India: wire harness and electronics sub-assembly, built in Bengaluru

Star Automations is a cable harness manufacturer for customers across India. We make wire harnesses, cable assemblies and electronics sub-assemblies at our own facility of about 7,000 sq ft in Mahadevapura, Bengaluru. We build to your drawing, sample or wiring list for drones and UAVs, EVs and BLDC motors, IoT devices, defence and industrial machines. Workmanship follows IPC/WHMA-A-620, and every harness is continuity and hi-pot tested before dispatch. We can supply UL-certified and EU-certified components for harnesses that must meet those requirements. Prototypes, small batches and repeat production.

Technicians assembling cable harnesses at the Star Automations facility in Mahadevapura, Bengaluru
Harness assembly benches at our Bengaluru facility.

Wire harness manufacturer in Bengaluru: at a glance

A wire harness (also called a wiring harness or cable harness) is a set of wires, terminals, connectors and sleeving bundled to a drawing so a product can be wired in one step. Last updated 6 November 2026.

MakerStar Automations, in business since 2000, ISO 9001:2015 certified
FacilityAbout 7,000 sq ft, Mahadevapura, Bengaluru 560048 (near Whitefield)
What we makeCustom wire harnesses, cable assemblies, battery and power cables, sensor and encoder leads, RF and coaxial assemblies, box build, panel wiring
Built forDrone and UAV makers, EV and battery storage makers, servo motor and drive OEMs, robot makers, IoT, defence, medical and industrial machines
Build toYour drawing, sample, photo or wiring list; we can prepare the drawing
QualityIPC/WHMA-A-620 workmanship; every harness continuity tested and hi-pot tested
Certified partsUL-certified and EU-certified (RoHS, REACH, CE where covered) components on request; see certified components
Order sizesPrototype and low-volume orders through repeat production
QuoteSend drawings or WhatsApp +91 97866 22233
01What we build

Harnesses, cable assemblies and sub-assemblies

One supplier in Bengaluru for the wiring inside your product, from a single lead to a wired and tested sub-assembly.

Wire and cable harnesses

Multi-branch harnesses built on harness boards to your drawing, with sleeving, ties, labels and connector housings.

Power and battery cables

Crimped lug cables, battery interconnects and power leads, with heat-shrink and printed identification.

Signal and sensor leads

Connector-to-connector signal leads, sensor cables, encoder and Hall sensor leads and fine-pitch wire-to-board connectors.

RF and coaxial cable assemblies

Coaxial and RF cable assemblies made to the connector, cable type and length on your drawing.

Electronics sub-assembly and box build

Harnesses, PCBs, power supplies, DIN-rail parts and terminals fitted and wired into an enclosure, ready to install.

Wire harness vs cable assembly: what is the difference?

The two terms overlap, and buyers use them interchangeably. Here is how we use them, so your quote request is clear.

Wire harness (wiring harness)

Several wires bundled and routed together, with branches, connectors, terminals and sleeving, laid out to a drawing. Typical for a drone, an EV, a machine or a control box, where many circuits run from one point to many.

Cable assembly

One jacketed cable (or a few) with connectors fitted at the ends, then tested. Typical for sensor, encoder, power, RF and coaxial leads that join two points.

Which one do you need?

If you are not sure, send a photo, a sample or a wiring list. We tell you which it is, prepare the drawing and quote it. A wire harness assembly and a cable assembly can ship together in one order.

02Sectors

Who we make harnesses for

Bengaluru is home to many drone, EV, IoT and defence electronics teams. We support them from prototype to repeat batches.

Drones and UAVs

Lightweight power distribution, ESC-to-motor, battery, payload and flight-controller signal harnesses for airframes and ground equipment. We also repair drone motors.

EVs and BLDC motors

Motor phase leads, Hall sensor and encoder leads, controller and battery harnesses for e-mobility and BLDC drives. Star also makes BLDC motors and solutions.

IoT devices and gateways

Sensor leads, wire-to-board connectors, power leads and internal harnesses for IoT devices, data loggers, gateways and smart meters.

Defence and aerospace electronics

Harnesses built to the customer's drawings, specification and inspection requirements, with traceable labelling.

Industrial machines and automation

Servo, encoder and control cables, machine harnesses and panel wiring for machine builders and system integrators.

Medical, lab and railway electronics

Internal harnesses and leads for medical and laboratory equipment and railway electronics, built to the customer's drawing.

Custom wire harness for new builds: drone, EV, battery storage, servo and robot makers

Starting a new product? We make a custom wire harness from a sketch, sample or wiring list, from one prototype to repeat batches, at our Bengaluru facility.

Drone and UAV makers

Power distribution, battery, ESC-to-motor, payload and flight-controller harnesses, built light and labelled for fast assembly.

EV and battery storage makers

Battery pack and BMS sense harnesses, power cables with crimped lugs, and cabling for energy storage cabinets, to your drawing and connector choice.

Servo motor and servo drive OEMs

Servo motor power cables, encoder and feedback cables, and drive-to-controller leads, built to your connector pinout.

Robot and automation OEMs

Robot arm and joint harnesses, sensor and I/O leads and control box wiring, made to fit your routing and flex needs.

  • Prototype and low-volume orders accepted, with the first article sent for your approval before the batch
  • Send a drawing, a sample, a photo or a wiring list; we prepare the drawing and bill of materials
  • Continuity and hi-pot tested, built to IPC/WHMA-A-620 workmanship
  • Based in Mahadevapura, Bengaluru, with easy access for teams in Whitefield, Marathahalli and Electronic City
03Engineering

Harness design support, from a sample or a wiring list

No drawing yet? Send a sample, a photo, a wiring list or a schematic.

  • Harness drawing and bill of materials prepared from your sample, wiring list or schematic
  • Connector, terminal, wire gauge and sleeving selection to suit current, flex and space
  • Design-for-manufacture review of lengths, branch points and labels before production
  • First article built and shared for your approval before the batch
  • Drawing revisions kept on file for repeat orders
Multi-branch wire harness with labelled terminals laid out on a harness board
A multi-branch harness laid out to drawing.

How a wire harness is designed and built

The same steps apply whether you need one prototype or a repeat batch.

  1. Define the circuits. List every signal and power line with its voltage, current and the two points it connects.
  2. Choose wire and connectors. Select wire gauge for the current and flex, then connectors, terminals and seals for the environment.
  3. Draw the harness. Set lengths, branch points, sleeving and labels on a harness drawing with a bill of materials.
  4. Review for manufacture. Check bend radius, routing, crimp access and test points before cutting wire.
  5. Build a first article. Cut, strip, crimp and assemble on a harness board, then share it for approval.
  6. Test and dispatch. Continuity test every harness, hi-pot test where required, label and pack.
04How it works

From drawing to dispatch

  1. Share the requirement. Drawing, sample or wiring list, quantity, connector part numbers and test needs.
  2. Review and quote. We check connectors, wire gauge, lengths and labels, raise any questions, then quote.
  3. First article. One harness built and sent for your approval.
  4. Production. Cut, strip, crimp and assemble on harness boards to the approved sample.
  5. Test and inspect. Continuity and hi-pot test, visual inspection to IPC/WHMA-A-620.
  6. Label and dispatch. Identified, packed and shipped across India or for export.
05Facility

Inside our Bengaluru facility

About 7,000 sq ft in Mahadevapura, near Whitefield, with assembly benches, crimping machines and a cable store.

Rows of harness assembly benches at the Star Automations Bengaluru facility
Harness assembly benches
Technician working beside terminal crimping machines in the Bengaluru harness facility
Terminal crimping
Cable reels and component racks in the stores of the Bengaluru facility
Cable and component stores
Production floor of the Star Automations facility in Mahadevapura, Bengaluru
Production floor
Signal and power cable assemblies with connectors made by Star Automations
Signal and power cable assemblies
Crimped lug power cables with printed identification sleeves
Lug power cables with identification
Sensor and wire-to-board connector leads made to drawing
Sensor and wire-to-board leads
Shielded cable assemblies with moulded connectors
Shielded connector leads
Labelled and dressed wiring on a DIN-rail electronics sub-assembly
Wired DIN-rail sub-assembly
Technicians wiring a control panel enclosure
Panel wiring
Technician inspecting an electronic board under a digital microscope with a board test system
Board inspection and test
Magnified view of a printed circuit board on an inspection monitor
Magnified inspection of sub-assemblies
06Quality

Built and tested to IPC/WHMA-A-620

Workmanship follows IPC/WHMA-A-620, the requirements and acceptance standard for cable and wire harness assemblies.

  • Crimp, strip and termination to IPC/WHMA-A-620 workmanship requirements
  • Continuity test of every harness
  • Hi-pot (dielectric) test
  • Labelling and identification to your drawing
  • ESD-protected handling where the assembly calls for it
  • Any extra tests, such as RF checks, agreed with you at quote stage

UL-certified and EU-certified components for your harness

If your product must meet UL or EU requirements, tell us at quote stage. We build the harness with UL-certified wire, cable, connectors, terminals and sleeving, and with EU-certified components, and we quote only parts that carry the certification you asked for.

PartUL-certified optionEU-certified option
Wire and cableUL style numbers such as UL 1007, UL 1015, UL 1061. Voltage and temperature rating depend on the style.RoHS and REACH compliant wire and cable.
Connectors and terminalsUL-recognised housings, contacts and terminals.RoHS and REACH compliant connectors; CE-marked parts where the part is covered.
Sleeving and heat shrinkUL-recognised flame-retardant sleeving and heat shrink.RoHS compliant sleeving, halogen-free options.
Finished harnessBuilt to your drawing with UL-certified parts. Whether the whole assembly needs UL recognition depends on your end product; we discuss it at quote stage.Built with EU-compliant parts for equipment sold in the EU. The CE mark stays with the equipment maker.

More detail on UL-certified and EU-certified cable harness parts. Send your drawing and the certification you need to the quote form.

Also known as

Buyers search for this work under many names. We make all of these in Bengaluru:

  • Wire harness manufacturer
  • Wiring harness
  • Cable assembly
  • Drone wiring harness
  • UAV harness
  • EV wiring harness
  • BLDC motor harness
  • Battery cable assembly
  • IoT cable assembly
  • RF cable assembly
  • Coaxial cable assembly
  • Sensor cable
  • Electronics sub-assembly
  • Box build
  • Electronics contract manufacturing
  • Panel wiring
  • Prototype harness
  • Low-volume harness production
  • Wire harness assembly
  • Custom wire harness
  • Wire harness design
  • Wire harness manufacturers in Bangalore
  • Cable harness manufacturers in India
  • BMS wiring harness
  • Energy storage cable harness
  • Servo motor cable
  • Servo encoder cable
  • Robot wiring harness
07Questions

Cable harness questions

Need the full panel? See control panel manufacturing.

Where is your cable harness facility in Bengaluru?

Our facility of about 7,000 sq ft is at 40, 1st Floor, Sparkling Nest Road, Lakshmi Sagar Layout, Mahadevapura, Bengaluru 560048, near Whitefield.

Do you make wiring harnesses for drones and UAVs?

Yes. We make lightweight power distribution, battery, ESC-to-motor, payload and flight-controller signal harnesses to your drawing or sample, from prototypes to repeat batches.

Do you make harnesses for EV and BLDC motor applications?

Yes. Motor phase leads, Hall sensor and encoder leads, controller harnesses and battery cables with crimped lugs. Star also makes BLDC motors, so the motor and its harness can come from one supplier.

Can you make cable assemblies for IoT devices?

Yes. Sensor leads, wire-to-board connector leads, power leads and internal harnesses for IoT devices, data loggers and gateways, built to your drawing.

Do you make RF and coaxial cable assemblies?

Yes, to the connector, cable type and length on your drawing. Continuity and insulation are checked on every assembly; any RF performance test is agreed with you at quote stage.

Do you offer electronics sub-assembly and box build?

Yes. We fit and wire harnesses, PCBs, power supplies, DIN-rail components and terminals into an enclosure and test the finished sub-assembly. For full control panels see our control panel manufacturing page.

Can you design the harness if I only have a sample?

Yes. We prepare the harness drawing and bill of materials from your sample, wiring list or schematic, and share it with a first article for your approval before production.

Is there a minimum order quantity?

We make prototypes and small batches as well as repeat production. Tell us the quantity and we quote for it.

How are harnesses tested?

Every harness is continuity tested and hi-pot tested before dispatch, and workmanship follows IPC/WHMA-A-620.

Do you supply outside Bengaluru?

Yes. We ship across India and also supply for export.

What should I send for a quote?

A drawing, sample or photo, the quantity, connector and terminal part numbers, the cable specification, any test requirements and your target date.

What is the difference between a wire harness and a cable assembly?

A wire harness bundles many wires with branches, connectors and sleeving to a drawing, for example inside a drone or a machine. A cable assembly is a single cable with connectors at the ends, such as an encoder or sensor lead. We make both and can supply them in one order.

Can you make a custom wire harness for a new product or prototype?

Yes. Send a sketch, sample, photo or wiring list and we prepare the drawing and bill of materials, build a first article for your approval, then produce the batch. Prototype and low-volume orders are accepted.

Do you make harnesses for battery storage and BMS applications?

Yes. We make battery pack and BMS sense harnesses and power cabling with crimped lugs, to your drawing, connector choice and wire gauge.

Can you make servo motor power and encoder cables?

Yes. Send the connector pinout or a sample cable and we build servo motor power cables, encoder and feedback cables and drive-to-controller leads.

Do you make wire harnesses for robots?

Yes. Robot arm and joint harnesses, sensor and I/O leads and control box wiring, built to your routing, length and flex requirements.

How is a wire harness quoted, and what is the price?

Price depends on the number of circuits, wire gauge, connectors, length, testing and quantity. Send a drawing, sample or wiring list with the quantity and we quote against it.

Can you supply UL-certified parts for a wire harness?

Yes. We build harnesses with UL-certified wire, cable, connectors, terminals and sleeving. Send the UL style number or your requirement (for example UL 1007, UL 1015 or UL 1061 wire) with the drawing, and we quote only parts that carry it.

Is the finished wire harness UL certified?

The parts we use can be UL-certified. Whether the finished assembly needs its own UL recognition depends on your end product and the UL programme it falls under. Send the details with your enquiry and we tell you what is possible.

Can you supply EU-certified or EU-compliant components?

Yes. We can build with components that meet EU requirements, such as RoHS and REACH compliant wire, cable, connectors and sleeving, and CE-marked parts where the part is covered. Tell us the directive or customer standard at quote stage.

Do you build harnesses for products exported to the USA, Canada or the EU?

Yes. If your product is exported, give us the target market and any UL or EU requirement. We choose certified components to match and keep to your drawing and IPC/WHMA-A-620 workmanship.

What is the difference between a UL-listed part and a UL-recognised part?

UL Listed products are certified as complete products for direct use. UL Recognized components, such as wire styles, connectors and sleeving, are certified to be used inside another product. Most harness parts are UL Recognized components.

Also repaired at Star Automations: power electronics, e-mobility and solar

We also build and repair harnesses and looms for e-mobility: EV powertrain and BMS looms, and the electronics that go with them. Send the model and fault and we confirm repairability before you ship.

UPS repair

Online, line-interactive and industrial UPS boards.

Send your harness drawing or sample.

Email info@starautomations.com, call sales on +91 95855 50109 or WhatsApp a photo.