Transport Cable Assemblies

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Cable assemblies for rail, commercial vehicles and automotive systems

Cable Assemblies Built for Transport

Transport networks and automotive systems demand cable assemblies engineered to withstand continuous operational wear. From high-speed rail passenger cars to commercial vehicle engine bays, electrical systems must operate continuously under relentless vibration, thermal cycling, and exposure to the elements.

Flair Electronics manufactures bespoke transport cable assemblies built to survive tough transit conditions through:

  • Vibration & Mechanical Shock Resistance: Ruggedised strain reliefs, robust latched or threaded connectors, and lacing/sleeving engineered to withstand continuous vehicle chassis vibration.
  • Fire Safety & Low Toxicity (EN 45545-2): Fire-retardant, Low Smoke Zero Halogen (LSZH) cable materials compliant with strict European rail safety standards to protect passengers and infrastructure.
  • Thermal & Chemical Endurance: Automotive and heavy-duty jacketing materials selected for resistance to engine heat, fuels, hydraulic fluids, battery acids, and road salts.
  • Sealed Environmental Protection (IP67/IP68/IP69K): Overmoulded connectors and potted backshells engineered to prevent water, mud, and dust ingress in exposed under-chassis and exterior installations.

Our Transport & Automotive Cabling Capabilities

  • Rail & Rolling Stock Harnesses: Multi-core power, inter-car jumpers, door control, signaling, and passenger information system (PIS) cable assemblies.
  • Commercial & Specialty Vehicle Looms: Heavy-duty wiring looms for buses, trucks, agricultural machinery, construction equipment, and emergency vehicles.
  • Electric Vehicle (EV) & Battery Cabling: High-voltage cable assemblies, battery management system (BMS) harnesses, and charging infrastructure wiring.
  • Automotive Control & Sensor Assemblies: Low-noise, shielded cable looms for CAN bus systems, ECU connections, telematics, and onboard sensor arrays.
  • Panel Integration & Sub-Assemblies: Full assembly and wiring of driver control consoles, junction boxes, and distribution panels.
European Cable Assembly 5
UK Cable Assembly 6
European Cable Assembly 3
UK Cable Assembly 4
European Cable Assembly 1
UK Cable Assembly 2

UK Engineering & European Scale

  • Flair Electronics provides automotive OEMs, rail contractors, and transport system integrators with a flexible production model balancing fast-turn engineering with volume manufacturing:

    1. UK Facility (Hitchin): Engineering Support & NPI
      • Rapid-turn prototyping and New Product Introduction (NPI) for vehicle developments and fleet refurbishments.
      • Direct technical assistance for schematic review, automotive/rail component selection, and DFM optimization.
      • Dedicated capability for low-to-medium volume, high-mix custom vehicle builds.
    2. European Facilities: Volume Production
      • Scaled manufacturing capacity for high-volume automotive, commercial vehicle, and mass-transit production runs.
      • Established inventory management options including scheduled buffer stock and call-off orders.
      • Direct transfer of validated designs from UK engineering lines to European volume production.

Frequently Asked Questions

Q: Do you supply cable assemblies compliant with EN 45545-2 rail fire safety standards?

  • A:  Yes. We source certified Low Smoke Zero Halogen (LSZH) cables and fire-retardant conduits specifically tested to comply with EN 45545-2 requirements for rail rolling stock.

Q: Can you manufacture high-voltage cable assemblies for electric vehicles (EV)?

  • A: Yes. We build custom high-voltage orange cable assemblies and BMS harnesses, incorporating shielded cabling and high-voltage automotive connectors.

Q: Do you support low-volume prototyping for niche commercial or emergency vehicles?

  • A: Absolutely. Our UK facility specialises in rapid NPI and low-volume, high-mix builds, allowing you to prototype and validate designs before committing to volume production.

Discuss Your Transport Cabling Requirements

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We hold ISO9001:2015 for the assembly of printed circuit boards and cable assemblies.  We follow the IPC 620 wire harness and cable assembly  guidelines using our own certified trainer. To learn more about our certifications please click here.