Custom JST Wire Harnesses

High-Density JST Micro-Pitch Harnesses

As modern electronics shrink in size, internal routing requires extreme precision. TeleWire operates advanced micro-processing machinery capable of terminating ultra-fine wire gauges to JST's most compact, low-profile connector families. These harnesses are essential for densely packed PCBs, EV Battery Management Systems (BMS), and advanced robotics.

Precision JST Families Supported:

  • SH & GH Series (1.0mm - 1.25mm Pitch): Ultra-compact routing with secure locking mechanisms for high-vibration chassis.
  • PH & XH Series (2.0mm - 2.5mm Pitch): Highly reliable, high-volume wire-to-board standard connections.
  • SM Series: High-density wire-to-wire internal interconnects.
JST VH and VHR Series wire harness with different pin numbers

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Supported Series & Part Numbers

We maintain extensive tooling and automated processing capabilities for the following industry-standard interconnects. If your specific part number is not listed, contact engineering for 1:1 cross-referencing.

Connector Series Pitch (mm / inch) Key Part Numbers Ideal Application
JST SUR Series (IDC) 0.80mm (.031")
02SUR-32S03SUR-32S04SUR-32SBM02B-SURS-TFSM02B-SURS-TF
 Ultra-miniature, mass-terminated IDC routing for extreme space constraints in consumer electronics.
JST SH Series 1.00mm (.039")
SHR-02V-S-BSHR-03V-S-BSHR-04V-S-BBM02B-SRSS-TBSM02B-SRSS-TB
 Ultra-compact, low-profile wire-to-board routing for drones, medical displays, and compact PCBs.
JST VH Series 3.96mm (.156")
VHR-2NVHR-3NVHR-4NB2P-VHB3P-VH
 Unsealed, heavy-duty internal power routing (Up to 10A) with friction locks for washing machines and large appliances.
JST SHD Series 1.00mm (.039") Double Row
SHDR-20V-S-BSHDR-30V-S-BBM20B-SRDS-G-TFBM30B-SRDS-G-TF
 High-density, double-row wire-to-board routing for complex multi-signal electronic chassis.
JST GH Series 1.25mm (.049")
GHR-02V-SGHR-03V-SGHR-04V-SBM02B-GHS-TBTSM02B-GHS-TB
 Secure, positive-locking connections preventing disconnects in high-vibration PDP, LCD, and drone chassis.
JST ZH Series 1.50mm (.059")
ZHR-2ZHR-3ZHR-4B2B-ZRS2B-ZR
 Space-saving, highly reliable discrete wire arrays for densely populated instrumentation panels.
JST PH Series 2.00mm (.079")
PHR-2PHR-3PHR-4B2B-PH-K-SS2B-PH-K-S
 The global standard for high-volume signal transmission in appliances, IoT devices, and battery packs.
JST PA Series 2.00mm (.079") Secure Lock
PAP-02V-SPAP-03V-SPAP-04V-SB02B-PASKS02B-PASK-2
 High-vibration internal routing featuring a secure locking device to prevent accidental disconnection.
JST XH Series 2.50mm (.098")
XHP-2XHP-3XHP-4B2B-XH-AS2B-XH-A
 Reliable, high-retention power routing commonly used in RC battery packs and Battery Management Systems (BMS).
JST EH Series 2.50mm (.098")
EHR-2EHR-3EHR-4B2B-EH-AS2B-EH
 Slim, polarized wire-to-board arrays preventing misinsertion in telecommunications and power supply boards.
JST SM Series 2.50mm (.098") Wire-to-Wire
SMP-02V-BCSMP-03V-BCSMR-02V-BSMR-03V-B
 High-retention wire-to-wire internal power distribution, commonly used in LED strip lighting and automotive accents.
JST JWPF Series 2.00mm (.079") Waterproof
02R-JWPF-VSLE-S03R-JWPF-VSLE-S02T-JWPF-VSLE-S
 IP67 sealed waterproof wire-to-wire connections designed for automotive, marine, and harsh environment sensing.

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Manufacturing of unlisted custom assemblies
Support for complex wire harnesses
Rapid prototyping for new designs
Equivalent alternatives for obsolete parts
Same-day engineering review
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Technical FAQs

Common questions from procurement and engineering teams.

What is the smallest pitch JST wire harness you can manufacture?

A: We manufacture internal wiring utilizing the JST SH series, which features an ultra-compact 1.0mm pitch. This requires specialized micro-processing of 28 AWG to 32 AWG wires, ideal for miniature PCB routing.

Why are JST GH and XH harnesses preferred for Battery Management Systems (BMS)?

A: The JST GH (1.25mm) and XH (2.50mm) series feature positive locking mechanisms. This ensures the wire harness will not disconnect due to the severe vibration commonly found in EV battery packs and drone chassis, maintaining critical sensor data flow.

How do you prevent wire breakage on ultra-fine JST internal wiring? 

A: Stripping 32 AWG wire manually often nicks the conductors. We eliminate this risk by utilizing fully programmable Schleuniger rotary stripping machines and verifying the terminal compression via continuous micrographic cross-sectional analysis.

Can you source genuine JST contacts and housings during global shortages? 

A: We maintains a robust, global supply chain network and extensive safety stock of high-runner JST series components. In extreme shortage situations, we can also validate and procure precision 1:1 mating equivalents to keep your production moving.

Manufacturing Standards & Capabilities

ISO 9001 Certified Factory

TeleWire Technology operates under strict ISO 9001 Quality Management Systems. Every production run undergoes rigorous IQC (Incoming Quality Control) and IPQC (In-Process Quality Control) to ensure consistent, OEM-grade reliability for global supply chains.

IPC/WHMA-A-620 Compliance

Our assembly technicians adhere to IPC/WHMA-A-620 standards for cable and wire harness fabrication. We guarantee precision crimp height, pull-force retention, and strain relief integrity for high-vibration automotive and industrial environments.

100% Electrical Testing

Zero defect policy. 100% of finished assemblies undergo automated testing for continuity, shorts, and mis-wiring. For critical safety applications, we provide advanced VSWR testing, high-pot testing, and insertion force validation.

Custom Component Sourcing

We source genuine connectors from Amphenol, TE Connectivity, Molex, and JST, or provide cost-effective, high-quality equivalents to meet your BOM targets. Our engineering team supports rapid prototyping with low MOQs and fast turnaround times.

Have 2D or 3D drawings ready?

Talk to our engineering team for immediate design validation and DFM (Design for Manufacturing) support.

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