Custom Molex Wire Harnesses

Precision Internal Routing with Molex Interconnects

As a leading contract manufacturer, TeleWire Technology specializes in high-volume, automated production of custom Molex wire harnesses. Designed for complex internal chassis routing, our assemblies provide secure, high-retention power and signal distribution for consumer electronics, industrial appliances, and server infrastructure.

Supported Molex Connector Series:

  • Mini-Fit Jr.™ & Mega-Fit®: High-current internal power distribution up to 23A.
  • Micro-Fit 3.0™ & Nano-Fit™: High-density, space-saving signal routing.
  • KK® 254 & KK® 396: Cost-effective, highly reliable wire-to-board solutions.
Custom Molex Wire Harnesses

Looking for Custom Wire Harnesses & Cable Assembly ?

Submit your technical requirements and project details, and our engineering team will review your request and respond within 24 hours.

Request Custom Quote

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) Supported Receptacles / Housings Ideal Application
Molex PicoBlade™ 1.25mm (.049")
5102151047510225326153398530475304851146
 Ultra-compact wire-to-board routing for tight chassis, drones, and medical displays.
Molex Micro-Fit 3.0™ 3.00mm (.118")
430254364543020436404304543650
 High-density signal and mid-range power routing (Up to 8.5A) for servers and industrial equipment.
Molex Mini-Fit Jr.™ 4.20mm (.165")
55575559556655694240442440
 The global standard for high-current internal power distribution (Up to 13A) in white goods, servers, and ATX power.
Molex KK® 254 2.54mm (.100")
2695647178804030423754237743804705347054
 Cost-effective, high-volume standard signal transmission for consumer electronics and HVAC controls.
Molex KK® 396 3.96mm (.156")
21393069416954167141672416614166231903192
 High-vibration internal power routing (Up to 7A) for heavy industrial appliances and vending machines.
Molex CLIK-Mate™ 1.25mm / 1.50mm / 2.00mm
502578503149502439502584503153502585503154505406505405
 Secure, positive-locking mating for automotive LED arrays and high-vibration smart meter displays.
Molex Nano-Fit™ 2.50mm (.098")
105307105308105309105311105310105312105313105314
 Fully isolated, compact power routing (Up to 8A) preventing cross-mating and short circuits in telecom.
Molex SL™ (Stackable Linear) 2.54mm (.100")
7006670107704007054370553705457063471192
 Modular, low-profile wire-to-board and wire-to-wire arrays for robotics and automotive dashboard panels.
Molex Milli-Grid™ 2.00mm (.079")
5111087831878321511178783387568151118151119
 High-density data, signal arrays, and parallel board-to-board interconnects in networking hubs.
Molex Standard .062" Pin and Socket 3.68mm (.145")
162503-06-101103-06-102303-06-2023
 Rugged, standard power and signal wire-to-wire routing (Up to 5A) in household appliances.
Molex Standard .093" Pin and Socket 5.03mm (.198")
1545319103-09-102203-09-2022
 Mid-range power routing (Up to 14A) in industrial equipment, vending, and retro gaming cabinets.
Molex Mega-Fit® 5.70mm (.224")
1716921700011054111054157682517206476829172065
 Extreme high-power delivery (Up to 23A per circuit) for server racks, UPS systems, and heavy machinery.

Can't find the exact cable you need?

Our website lists only a fraction of our capabilities. We manufacture thousands of custom cable assemblies and wire harnesses not shown online. Upload your drawing or specs here, and we will build it for you.

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

Technical FAQs

Common questions from procurement and engineering teams.

What is the difference between Molex Mini-Fit Jr. and Micro-Fit 3.0 wire harnesses?

A: Mini-Fit Jr. harnesses utilize a 4.20mm pitch and are designed for higher-current internal power distribution (up to 13A per circuit). Micro-Fit 3.0 harnesses use a compact 3.00mm pitch, making them ideal for high-density signal routing where chassis space is limited.

Do your custom Molex wire harnesses meet UL standards?

A: Yes. All our Molex internal wire harnesses are manufactured using UL-listed wire (such as UL1007 or UL1015). Our automated crimping lines utilize Crimp Force Monitoring (CFM) to guarantee 100% compliance with strict UL 486A-B tensile strength and safety standards.

Can you manufacture complex multi-breakout Molex routing architectures?

A: Absolutely. Using automated equipment and custom assembly boards, we fabricate complex internal wiring topologies with dozens of precise breakout points, allowing for seamless integration across multiple PCBs, fans, and sensors within a single enclosure.

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.

Request Technical Quote →