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Automotive Wires and Thin-Wall Primary Cables

Automotive primary wires and low-voltage electrical cables manufactured to SAE J1128, ISO 6722, and JASO M405 standards. Built with bare or tinned stranded copper conductors and thin-wall PVC, XLPE, or fluoropolymer insulation, these cables provide stable electrical conductivity, fluid resistance, and thermal endurance from -40 deg C up to +150 deg C.

We supply standard primary automotive wires, cross-linked battery cables, and high-voltage shielded wires for electric vehicles (EV), optimized for automated cutting, stripping, and terminal crimping equipment.

Wire for Automotive Use
wire for automotive use is a flexible automotive wiring solution with high mechanical strength, excellent chemical resistance, and stable electrical properties. Suitable for automotive circuits,
Automotive Copper Wire
automotive copper wire is a low-voltage automotive cable with oxygen-free copper conductor and 105°C heat-resistant PVC insulation. It offers excellent oil resistance, scratch resistance, and

Product Categories

SAE Primary Wires (TXL, GXL, SXL, GPT):

Cross-linked polyethylene (XLPE) and PVC insulated single-conductor wires. TXL features an extra-thin wall design for high-density harness routing through vehicle bulkheads.

ISO Metric Thin-Wall Cables (FLRY-A, FLRY-B, FLR2X):

Standard European vehicle wires. FLRY-A uses concentric copper stranding for tight OD control; FLRY-B uses flexible stranding for dynamic routing in door hinges and tailgates.

High-Voltage EV Cables (Orange Shielded 600V/1000V):

Multi-core and single-core orange jacketed cables with aluminum foil and tinned copper braid shielding for electric vehicle battery packs, inverters, and PDU connections.

Specifications and Construction

Parameter / Wire Type	TXL (SAE J1128)	FLRY-B (ISO 6722)	SGX (SAE J1127)	EV HV Shielded Wire
Conductor Material	Stranded Bare Copper	Stranded Bare Copper	Bare / Tinned Copper	Tinned Annealed Copper
Conductor Gauge / Size	22–8 AWG	0.35–6.0 mm²	6 AWG–4/0 AWG	2.5–120 mm²
Insulation Material	XLPE (Cross-Linked PE)	PVC (Thin-Wall)	XLPE (Cross-Linked PE)	Orange XLPE / Silicone
Shielding Construction	Unshielded	Unshielded	Unshielded	Aluminum Foil + Tinned Copper Braid (≥85%)
Voltage Rating	60 V DC / 25 V AC	60 V DC / 25 V AC	60 V DC	600 V / 1000 V DC
Operating Temperature	-40°C to +125°C	-40°C to +105°C	-40°C to +125°C	-40°C to +150°C
Fluid Resistance	Engine oil, fuel, fluids	Engine oil, diesel, acid	Engine oil, battery acid	Coolant, transmission fluid
Wall Thickness Class	Extra Thin Wall	Thin Wall (Type B)	Standard Battery Wall	Dual-Layer Reinforced Wall
Automated Process Compatibility	High (Komax / Schleuniger)	High (Komax / Schleuniger)	Standard Heavy Crimping	High-Precision Stripping

Application and Working Conditions

Engine Compartments and Powertrain:

XLPE-insulated wires (TXL, SGX) resist ambient temperatures up to +125 deg C and direct exposure to engine oil, gasoline, and hot grease without insulation swelling.

Cabin, Dashboard, and Door Panels

FLRY-A and TXL thin-wall wires reduce total harness bundle weight and diameter, enabling tight bend radiuses inside cramped vehicle interiors.

Chassis, ABS, and Wheel Speed Sensors:

Abrasion-resistant PVC and TPE jacketed wires maintain structural integrity when exposed to road gravel, splash water, and sub-zero ice accumulation.

EV Powertrains and Charging Circuits:

High-voltage shielded cables mitigate electromagnetic interference (EMI) between traction motors, battery management systems (BMS), and onboard chargers.

Standards and Compliance

Quality Management: Certified to IATF 16949:2016 for automotive production and ISO 9001:2015.

Automotive OEM Specifications: Compliant with SAE J1128, SAE J1127, ISO 6722-1, JASO M405, and LV 112 requirements.

Material and Environmental Safety: Full compliance with EU RoHS 3 (Directive 2015/863), REACH SVHC requirements, and IMDS (International Material Data System) registration.

Flame Retardancy: Passes ISO 6722 self-extinguishing flame tests and UL VW-1 vertical flame exposure metrics.

Custom Cable and OEM Options

01/

Custom Color Coding and Striping: Solid insulation colors matching international vehicle wiring schematics, with single or dual longitudinal helical stripes for circuit identification.

02/

Custom Surface Marking: Sequential meter or foot marking, continuous ink-jet printing of custom part numbers, circuit designations, and wire gauges.

03/

Customized Stranding Configurations: High-flexibility stranding using ultra-fine copper wire for dynamic application zones such as steering columns and door hinges.

04/

Pre-Cut and Packaged Drums: Supply delivered on high-capacity barrels, plastic reels, or cardboard spools pre-configured for direct feed into automatic crimping machines.

Quality Control and Testing

Conductor Purity and Resistance Test:

99.99% pure oxygen-free copper rod analysis via optical emission specs; micro-ohmmeter testing ensures DC resistance matches SAE/ISO limits.

In-line Dual-Axis Laser Micrometer Control:

Continuous monitoring of insulation outer diameter and conductor concentricity (>=85%) to prevent terminal crimp failures on automatic wire processors.

Thermal Aging and Fluid Immersion Testing:

Oven baking tests verify thermal resistance at elevated temperatures; 20-hour fluid soak tests verify resistance to motor oil, brake fluid, and battery acid.

High-Voltage Spark and Dielectric Testing:

100% inline spark testing at 3.0 kV to 10.0 kV detects pinholes, micro-cracks, and insulation voids prior to spooling.

Packaging and Delivery

Packaging Options:

Small Spools:

100 m / 305 m (1,000 ft) spools for bench top harness repair and low-volume specialty builds.

Pay-off Barrels / Drums:

2,000 m to 5,000 m heavy-duty drum packaging for high-speed automatic wire cutting machines.

Cargo Protection:

Moisture-barrier foil wrapping on IPPC-fumigated plywood pallets with plastic corner strapping.

Delivery Lead Time:

Standard TXL and FLRY wires in stock colors ship in 7-10 days. Custom striped or specialized EV cables ship in 14-21 days following PPAP approval.

FAQ

Q: What is the primary difference between TXL, GXL, and SXL automotive wires?

A: All three are SAE J1128 cross-linked polyethylene (XLPE) insulated wires rated to +125 deg C. The difference lies in insulation wall thickness: TXL features an extra-thin wall (smallest outer diameter and weight), GXL uses a thin wall, and SXL uses a standard thick wall for maximum mechanical protection.

Q: How do you guarantee concentricity for automatic wire processing machines?

A: We utilize dual-axis laser micrometers and inline magnetic eccentricity sensors during extrusion. Concentricity is held above 85%, ensuring that automatic wire cutting and stripping blades (such as Komax) do not score or nick copper strands.

Q: Can IMDS (International Material Data System) records be provided for vehicle approval processes?

A: Yes. As an IATF 16949 certified manufacturer, we upload full material composition data to the IMDS system for PPAP Level 3 submissions upon contract agreement.

Q: What is the benefit of XLPE insulation over standard PVC insulation in automotive wiring?

A: Cross-linked polyethylene (XLPE) undergoes a chemical cross-linking process that prevents the material from melting at high temperatures. It offers superior thermal endurance (+125 deg C to +150 deg C compared to PVC's +85 deg C to +105 deg C) and higher resistance to cut-through and engine fluids.

Q: What quality certificates and test reports accompany bulk automotive cable shipments?

A: Every shipment includes a Certificate of Analysis (COA) containing conductor DC resistance values, insulation outer diameter tolerances, spark test pass verification, and material batch traceability numbers.

Q: What key parameters should be provided when requesting a quote for automotive wire?

A: Please specify:
Wire standard and type (e.g., SAE TXL or ISO FLRY-B)
Conductor size (AWG or mm2 cross-section)
Insulation color and striping requirements (e.g., White with Black stripe)
Packaging type (plastic spools or continuous pay-off drums)
Target annual quantity and required compliance documentation (e.g., PPAP)

As one of the most professional automotive wiring manufacturers and suppliers in China, we also support customized service. Please feel free to buy bulk high quality automotive wiring in stock here from our factory. For price consultation, contact us.

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