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Custom Cable Assembly Solutions

Custom Cables and Cable Assemblies provide a wide range of custom cable assemblies and wire harnesses that include high power, overmolded and sealed off-the-shelf options that support all industries.

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Discrete-Wire Cable Assemblies

Discrete-Wire Cable Assemblies offer a range of options, such as single- or dual-ended, straight or branched, dressed, twisted and more, to meet a design’s specific requirements.

Available with a range of Molex and non-Molex connectors:
• Meets the needs of a range of applications
• Offers design flexibility

Molex engineers provide insightful design input:
• Support is provided throughout the product life cycle, including design, prototyping and production

Multiple configurations and cable management features available:
Eases cable routing and management. Options include:
• Single- and/or dual-ended
• Straight or branched into X or Y configurations
• Dressed with cable ties, heat-shrink tubing, cloth tape,  expandable woven sleeves, corrugated tubes and more
• Twisted
• Ferrite cores and labels

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High-Power Cable Assemblies

High-power cable assemblies offer discrete and overmolded cables, ranging from 6 to 12 AWG, and deliver medium- to high-voltage options, ranging from 300 to 600V.

Custom assemblies for production:
• Meet design needs after prototyping is complete
• Molex’s extensive design and manufacturing expertise can meet the unique challenges of the most demanding applications

UL-approved discrete wires:
• Ready to use in electronic appliance applications
• Provide ease of design, prototyping and production

Pin-to-pin mapping from receptacle to PCB header:
• Provides ready-to-use, plug-and-play connections

Assembled in ISO/TS16949-certified facilities:
• Ensures high quality
• Meets current automotive industry standards

Featured Products:
• EXTreme Guardian System: 80.0A per blade; EMI/RFI shielding
• Mega-Fit Discrete Wire and Overmolded Cable Assemblies: 23.0A; premium housing features
• EXTreme Ten60Power: 60.0A power blades

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Overmolded Cable Assemblies

Molex designs and manufactures custom overmolded cable assemblies in multiple circuit sizes and cable lengths, providing rugged strain relief at the interface between the connector and the jacketed cable.

Overmolded strain relief:
• Reduces mechanical stress on wires and terminals

Positive latching on housings:
• Prevents accidental disconnects

Clean body terminals:
• Protect against potential damage of terminals during handling and mating

Double-ended assemblies:
• Provide a variety of application options

Design flexibility:
• Various connector family options offer solutions based on size, current carrying capacity, wire style or circuit-size needs

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Picoflex Ribbon Cable Assemblies

Molex's Picoflex Ribbon Cable Assemblies offer a range of options using different insulation displacement termination (IDT) connector families from Molex, such as Picoflex and Milli-Grid.

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Sealed Cable Assemblies

Sealed Cable Assemblies, with an IP67- or IP69-rated connector at one end and a standard wire-to-board connector at the other, deliver reliable connectivity for harsh-environment applications.

Cable assemblies with NEMA-rated connectors:
• Provide up to IP69K protection for application in harsh conditions
• Enables reliable connection even in wet environments

Matte-seal design for all circuit sizes:
• Eliminates the need for cable wire seals

Panel-mount gasket seals:
• Protects against dust and water ingress to ensure reliable connection

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Wire Harnesses

Custom Wire Harnesses, with multiple breakouts and connectors, deliver a complete connectivity solution that meets a range of performance needs such as knowledgeable design support, optimal bill of materials, lower tooling costs and on-time production.

Mechanical and electrical designs, development, testing and prototyping support provided:
• Enables a complete cable assembly solution from one vendor
• Ensures quality and high performance

Overmold option available:
• Offers strain relief and cable protection
• Prevents water and dust ingress

IDT, crimp, solder and welded terminations:
• Wide variety provides application flexibility

Global manufacturing, material sourcing and tooling capabilities:
• Delivers one-stop solution for the design and manufacture of all harness needs

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RF Custom Cable Assembly Solutions

High-quality cable designs that can accommodate standard RG braided cables, micro coax, semi-rigid cable, vendor-specific custom cables, LMR types and hand-conformable cable solutions. Engineers will have access to RF cable assemblies that hold up against a myriad of challenging environments.

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Resources

Tools

Custom Cable Creator

Design your own cable harness with the Molex Custom Cable Configurator and  receive a concept drawing, 3D model, samples and/or a quote.

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RF Assembly Builder

Design RF cable assemblies from various connectors and cable types. Add additional specs and project requirements to create a customized design. 

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