Precision-engineered wiring harnesses for high-performance automotive applications

Precision-engineered wiring harnesses for high-performance automotive applications

8th August 2025 | 2 min read

The Challenge

Hyperbat, a leading EV battery manufacturer, required a high-precision, safety-critical wiring harness solution for a high-performance automotive application. Existing suppliers struggled to meet the required stringent quality standards, full traceability, and manufacturing consistency, leading to supply chain inefficiencies, quality concerns, and production delays.

To address this, Hyperbat sought a trusted UK-based manufacturing partner with proven expertise in automotive-grade assembly, process control, and zero-defect manufacturing. The ideal supplier needed to deliver flawlessly, scale production seamlessly, and integrate with Hyperbat’s evolving engineering requirements.

The Solution

With nearly four decades of automotive manufacturing experience, Unipart applied its deep-rooted manufacturing expertise in complex, safety-critical assembly to deliver a fully controlled and scalable wiring harness production solution.

  • Manufacturing to automotive standards – Unipart’s wiring harness production is built to IPC620 standards, ensuring component-level compliance, while IATF 16949-certified Quality Management System governs process excellence and continuous improvement.
  • Engineering collaboration without overlap – While we are a build-to-print manufacturer, the dedicated engineering team worked alongside Hyperbat throughout production, offering insight into manufacturability, efficiency, and process optimisation.
  • Scalable, repeatable process control – Unipart’s lean manufacturing principles ensure that processes are right first time at every level, from low-volume prototyping to full-scale production.
  • End-to-end quality assurance – Automated controls, 100% testing and no-fault-forward manufacturing guaranteed complete traceability and zero-defect output.

The Impact

Unipart’s scalable wiring harness production solution provided a new benchmark for quality and responsiveness, which allowed Hyperbat to provide a high-quality, reliable and innovative solution to their end customer within tight timescales.

Features of the solution included:

  • UK-based, high-quality manufacturing capability – Eliminating reliance on overseas suppliers, reducing lead times from eight weeks to four weeks (a 50% reduction), and strengthening supply chain resilience.
  • Flawless, zero-defect production – Adhering to the same high-precision standards found across automotive safety-critical components.
  • Scalable, controlled processes – Designed to accommodate both prototype and production volumes without compromising quality or efficiency.
  • Responsive, agile supply partnership – Rapid turnaround on reworks, design adaptations, and urgent production demands.

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