Custom JST & Molex Wire Harness Assembly

A wire harness looks simple until it is expected to fit a real enclosure, mate reliably with a PCB, survive repeated handling and arrive ready for assembly. This product is built as a configurable cable assembly rather than a fixed off-the-shelf lead. Connector family, pin count, wire gauge, length, color sequence, terminal processing and labeling can all be matched to the application.

Typical configurations use copper conductors with JST or Molex-style connectors for electronics, control boards, sensors, motors, lighting assemblies and other low- or medium-voltage equipment. Standard examples are available from 1P to 6P and in common lengths from 100 to 300 mm. Custom layouts can be produced from a drawing, pinout, sample or clear written specification.

Built around the mating interface

The connector name alone is not enough to release a harness for production. Pitch, housing series, terminal type, pin count, mating direction and latch style must all match the equipment. Where a customer already has a PCB connector or mating plug, we recommend providing the exact part number or a clear photograph with dimensions.

Assemblies can be supplied single-ended, double-ended, branched or with stripped and tinned wire ends. JST and Molex options cover many common applications, while alternative connector and terminal families can be evaluated for OEM projects.

Configurable cable construction

• Pin count: 1P, 2P, 3P, 4P, 5P and 6P standard configurations.

• Length: common lengths include 100, 120, 150, 200, 250 and 300 mm; other lengths can be specified.

• Conductor: copper-core wire selected to suit current, flexibility and termination requirements.

• Insulation: PVC, PTFE, rubber and PET options depending on temperature, flexibility and environment.

• Wire identification: custom colors, stripes, labels or numbered markers can be used to support assembly and service.

• Termination: connector-to-connector, connector-to-open-wire, stripped, tinned or other application-specific end processing.

Rated-voltage options shown for this product include 12, 24, 36, 110 and 220 V. The final voltage and current rating depends on the complete construction: wire gauge, insulation, terminal, connector spacing, temperature rise and applicable safety requirements. For mains-voltage projects, provide the destination market and compliance requirements before approval.

Applications

These harnesses are suitable for electronic equipment, PCB assemblies, computers, control panels, RF receivers, sensors, motors, fans, lighting products and small industrial devices. They are also useful as internal interconnects where a repeatable plug-in assembly reduces wiring errors during production.

For products exposed to vibration, frequent maintenance or operator handling, we can review locking connectors, strain relief, protective sleeving and cable routing requirements. A connector that works on a bench may still need additional retention in a moving machine.

Quality checks before shipment

Each production batch is checked against the approved drawing or reference sample. The normal inspection flow covers incoming materials, wire length and color, crimp condition, terminal position, housing orientation and finished appearance. Electrical continuity testing is performed on completed assemblies before shipment.

For critical pinouts, we recommend a documented first-article sample. The approved sample should identify connector orientation, cavity numbering, wire colors, length reference points, label position and any special electrical test. This prevents an apparently minor interpretation difference from becoming a full-batch rework.

What to send for a quotation

• connector manufacturer and series, or clear photos and dimensions;

• pin count and pin-to-pin wiring table;

• wire gauge, insulation type and color sequence;

• finished length and the points from which it is measured;

• voltage, normal current and any startup or surge current;

• operating temperature, movement, vibration or moisture exposure;

• labeling, sleeving, bundling and packaging requirements;

• sample quantity and expected production volume.

If a drawing is not available, send the mating components or an existing harness sample. We can help convert it into a production specification and confirm the points that affect fit, electrical performance and cost before samples are made.

OEM and ODM support

Custom labeling, packaging, wire colors, connector combinations and terminal processing are available. Small trial orders may be possible for standard constructions; MOQ and lead time for custom assemblies depend on material availability, tooling and inspection requirements.

For repeat production, the approved specification is retained as the manufacturing reference so later batches follow the same pinout and mechanical details. Contact ANRIVERS with your drawing, sample or application requirements for a project-specific recommendation and quotation.