How Are 1.0mm–2.54mm Harnesses Made?

Wire harness manufacturing is a precise process that combines electrical engineering, material science, and automated production. From 1.0mm micro-pitch to 2.54mm standard connectors, every harness must meet strict mechanical and electrical performance requirements. This article explores how manufacturers create reliable Custom Molex AMP TE JST 1.0mm 1.25mm 1.5mm 2.0mm 2.54mm Wire Harness assemblies from concept to completion.

1. Design & Engineering Planning

Every successful harness begins with a detailed design. Engineers analyze the application’s electrical load, current rating, and environmental conditions before selecting connector types and wire gauges. CAD software such as AutoCAD Electrical or EPLAN is used to map each circuit path.

During this phase, connector types like Molex Pico-Clasp 1.00 mm, JST GH 1.25 mm, and TE AMP Mini CT 1.5 mm are evaluated. Engineers ensure compatibility across brands while maintaining standardized spacing and terminal geometry.

• Pitch and pin count (1.0mm–2.54mm)

• Connector locking type (friction, latch, or positive-lock)

• Wire gauge (AWG 22–30 depending on load)

• Environmental protection (IP67 sealing, temperature rating)

2. Material Preparation

Once the design is validated, production begins with precise material preparation. Automated machines perform wire cutting, stripping, and crimping operations. Terminals are attached using precision presses calibrated to micrometer accuracy.

Wires and terminals are sourced from TE, Molex, or JST, ensuring tight tolerance and plating consistency. The base wires comply with UL 758 and ISO 19642, guaranteeing insulation reliability.

3. Connector Assembly

Connectors such as 1.0mm SMT header to receptacle harness, 1.25mm dual-row crimp housing, or 2.54mm KK 254 headers are assembled next. Operators or robotic systems insert each terminal into housings while verifying retention force and orientation.

• Molex PicoBlade 1.25 mm wire-to-board harness

• TE AMP CT 2.0 mm wire-to-board harness

• Molex KK 254 2.54 mm wire harness

Quality teams conduct random inspections with magnified optical systems to ensure proper seating and polarity.

4. Harness Layout and Routing

Wires are arranged according to a layout board (also called a jig or fixture). This board represents the exact physical layout of the final harness. Operators place the wires and connectors along pins that define routing paths, ensuring accuracy and repeatability.

Protective materials are applied such as braided PET sleeving, Nomex overbraid, heat-shrink tubing, or corrugated conduits. This stage transforms individual components into a fully structured Custom Molex AMP TE JST 1.0mm 1.25mm 1.5mm 2.0mm 2.54mm Wire Harness ready for testing.

5. Overmolding & Potting

For high-performance or outdoor applications, connectors and junction points are overmolded or potted. Overmolding uses thermoplastic materials to create a sealed strain relief, while potting involves epoxy or silicone compounds that protect from moisture and chemicals. This ensures longevity, especially in automotive, aerospace, or medical devices.

6. Testing & Quality Verification

Every harness undergoes 100% electrical testing before shipping, including:

• Continuity test: verifies every circuit connection.

• HiPot test: ensures insulation integrity under high voltage.

• Resistance test: measures contact resistance for consistency.

• Pull force test: confirms mechanical crimp strength.

Manufacturers certified under IATF 16949 and ISO 9001 maintain traceability through barcode systems and digital test reports, guaranteeing product safety and compliance.

7. Packaging & Documentation

Harnesses are coiled, labeled, and packed to prevent deformation during transport. Each batch includes identification labels, RoHS/REACH compliance certificates, and optional 3D drawings for customer reference.

8. Why Automation Matters

Modern production integrates automation at every level: robotic crimping, vision inspection, and automatic test benches. Automation ensures repeatability, accuracy, and high efficiency for micro-pitch harness manufacturing.

Conclusion

The production of 1.0mm–2.54mm wire harnesses merges design precision, automation, and strict quality control. Whether it’s a 1.0mm Pico-Clasp signal cable or a 2.54mm KK power harness, each assembly is meticulously engineered for performance and reliability.

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