Wire and cable harnesses
Multi-branch harnesses built on harness boards to your drawing, with sleeving, ties, labels and connector housings.
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. Prototypes, small batches and repeat production.
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.
| Maker | Star Automations, in business since 2000, ISO 9001:2015 certified |
|---|---|
| Facility | About 7,000 sq ft, Mahadevapura, Bengaluru 560048 (near Whitefield) |
| What we make | Custom wire harnesses, cable assemblies, battery and power cables, sensor and encoder leads, RF and coaxial assemblies, box build, panel wiring |
| Built for | Drone and UAV makers, EV and battery storage makers, servo motor and drive OEMs, robot makers, IoT, defence, medical and industrial machines |
| Build to | Your drawing, sample, photo or wiring list; we can prepare the drawing |
| Quality | IPC/WHMA-A-620 workmanship; every harness continuity tested and hi-pot tested |
| Order sizes | Prototype and low-volume orders through repeat production |
| Quote | Send 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.
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.
Panel and cabinet wiring
Ferruled, labelled and dressed wiring for control panels and cabinets. See control panel manufacturing.
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
How a wire harness is designed and built
The same steps apply whether you need one prototype or a repeat batch.
- Define the circuits. List every signal and power line with its voltage, current and the two points it connects.
- Choose wire and connectors. Select wire gauge for the current and flex, then connectors, terminals and seals for the environment.
- Draw the harness. Set lengths, branch points, sleeving and labels on a harness drawing with a bill of materials.
- Review for manufacture. Check bend radius, routing, crimp access and test points before cutting wire.
- Build a first article. Cut, strip, crimp and assemble on a harness board, then share it for approval.
- Test and dispatch. Continuity test every harness, hi-pot test where required, label and pack.
04How it works
From drawing to dispatch
- Share the requirement. Drawing, sample or wiring list, quantity, connector part numbers and test needs.
- Review and quote. We check connectors, wire gauge, lengths and labels, raise any questions, then quote.
- First article. One harness built and sent for your approval.
- Production. Cut, strip, crimp and assemble on harness boards to the approved sample.
- Test and inspect. Continuity and hi-pot test, visual inspection to IPC/WHMA-A-620.
- 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.
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
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
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.
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.
Inverter repair
Solar, hybrid, off-grid and home inverters.
UPS repair
Online, line-interactive and industrial UPS boards.
Lithium battery and BMS repair
BMS boards, packs and chargers.
EV charger repair
Portable, AC wall-box and small vehicle chargers.
EV traction motor and resolver
PMSM and BLDC traction motors, resolver and encoder faults.
BLDC and EV controller repair
Curtis, Zapi, hub-motor, EC fan and industrial BLDC drivers.
Send your harness drawing or sample.
Email info@starautomations.com, call sales on +91 95855 50109 or WhatsApp a photo.