A vehicle harness lives between two extremes: 600 °C radiant heat beside the exhaust and deep-cold flexibility at −60 °C — with abrasion, crush and, in EVs, high dielectric stress in between. This page maps each working condition to the sleeving construction that survives it.
Start from the working condition, not the catalogue. Each card below is a condition we engineer for again and again in automotive and EV programs.
Radiant and conducted heat near the exhaust and turbo can exceed what ordinary polymers tolerate. Silicone fiberglass sleeving is rated −60 ~ +200 °C (−76 ~ 392 °F) with 220 °C (428 °F) peak on selected constructions — and TGS-1W-600C takes routing beside hot sections up to 600 °C (1112 °F).
Cold-climate starts and refrigerated systems need insulation that does not stiffen or crack. Silicone rubber stays flexible at −60 °C (−76 °F) — a range where PVC and many elastomers turn rigid.
Harnesses passing brackets, grommets and panel edges see point loads and vibration. Woven fiberglass and expandable PET braid distribute those loads where a solid extruded wall can be nicked through.
High-voltage leads and battery internals need a dielectric barrier that keeps its properties across the full temperature range. Silicone fiberglass sleeving reaches up to 50 kV on selected constructions; PSR platinum-cured silicone tubing covers −60 ~ +200 °C (−76 ~ 392 °F).
Every row pairs a real harness position with the working condition at that spot and the WCW construction we recommend for it.
| Position | Working Condition | Recommended WCW Material | Key Rating |
|---|---|---|---|
| Engine compartment leads | Heat cycling, flexing at the exit | SGS / SRS silicone fiberglass sleeving | −60 ~ +200 °C (−76 ~ 392 °F), 220 °C (428 °F) peak selected |
| Routing beside exhaust & hot sections | Radiant heat beyond silicone's range | TGS-1W-600C high-temperature fiberglass sleeving | −60 ~ +600 °C (−76 ~ 1112 °F) |
| EV high-voltage leads | Dielectric stress across the temperature range | Silicone fiberglass sleeving, high-breakdown grades | 4–20 kV standard · up to 50 kV selected constructions |
| Leads needing a tough outer surface | Handling damage, chafe at the exit | GS sleeving — inside rubber / outside fiber | 7000 V avg / 6000 V min · UL 1441 E233804 (GS-WCW-70) |
| Battery pack & thermal-system tubing | Flexibility from −60 °C, clean insulation | PSR platinum-cured silicone tubing | −60 ~ +200 °C (−76 ~ 392 °F) |
| Body harness bundling | Crush, chafe, vibration along the route | PET expandable braided sleeving | −60 ~ +155 °C (−76 ~ 311 °F) · cut & abrasion resistant |
Six constructions cover every position on the harness — from the engine bay to the battery pack.
The harness workhorse: silicone-coated fiberglass, flexible at −60 °C, rated −60 ~ +200 °C (−76 ~ 392 °F) with 220 °C (428 °F) peak selected, UL 1441 with UL VW-1.
Smooth silicone-rubber outer skin over a fiberglass core; the E233803 style for lead protection where a sealed feel matters.
Rubber inside, braid outside: a tough outer surface for leads that get handled on the line. 7000 V avg / 6000 V min, UL 1441 E233804 (GS-WCW-70).
Pure silicone tubing for battery and thermal-system runs — flexible from −60 °C, rated −60 ~ +200 °C (−76 ~ 392 °F).
Bundling, identification and cut resistance along the body harness; expands over connectors, cuts cleanly.
For zones no silicone can reach — exhaust-adjacent and turbo-adjacent routing up to 600 °C (1112 °F).
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