Abstract: Production challenges of charging aluminum cables for new energy vehicles (NEVs)—including substandard conductor mechanical properties, insufficient insulation adhesion, and water absorption of nylon insulation—were addressed to mitigate their adverse effects on wire harness processing. Solutions were proposed through systematic process analysis and experimental verification: Conductor mechanical properties were optimized, reducing bending defects to below 7%; conductor preheating temperature was controlled at 190~200 °C to stabilize adhesion at 55~65 N, eliminating bulging and brittle cracks; nylon material was pre-dried to prevent insulation pores, high-voltage cracks, and conductor residue. Technical support was provided for standardized production and improved qualification rates in wire harness processing, advancing the "aluminum-for-copper" cost-saving strategy in NEVs.