Custom Jumper Wire Cable Assembly Manufacturer

OEM custom jumper wire cable assemblies with custom wire gauge, cable length, connector pitch, pin configuration, color sequence and terminal options for PCB, electronics and industrial applications.

Yihetai manufactures custom jumper wire cable assemblies for PCB connection, breadboard testing, sensor wiring, LED modules, industrial control equipment, smart devices and OEM electronic products. We can customize wire gauge, cable length, connector type, pitch, pin count, color sequence, terminal type, insulation material, labeling and packaging according to your drawing, sample or application requirement.

Whether you need male-to-male jumper wires, male-to-female jumper wires, female-to-female jumper wires, Dupont jumper wires, JST jumper wire assemblies, Molex jumper wires, IDC ribbon jumper cables or pre-crimped jumper wires, Yihetai can support prototype samples and mass production.

What Is a Jumper Wire?

A jumper wire cable assembly is a flexible electrical connection used to link PCB boards, modules, sensors, switches, displays, controllers and testing devices. It is commonly used for signal transmission, low-voltage power connection, circuit testing and internal wiring between electronic components.

Compared with standard off-the-shelf jumper wires, a custom jumper wire assembly can better match the actual equipment layout, connector pitch, pin configuration, color sequence and installation space. This helps improve assembly efficiency, reduce wiring mistakes and make production more stable for OEM electronic products.

Custom jumper wires can be made with different connector systems, wire gauges, insulation materials, terminal types and cable structures. They are widely used in PCB prototyping, industrial automation, robotics, smart home devices, battery systems, LED lighting and consumer electronics.

What Types of Jumper Wires Can We Manufacture?

1.Dupont Jumper Wire Assemblies
Yihetai manufactures custom Dupont jumper wires for PCB boards, electronic modules, testing fixtures, control boards and prototype-to-production applications. Options include male-to-male, female-to-female and male-to-female configurations. We can customize wire length, color sequence, pin layout and connector housing according to your requirements.

2.JST Jumper Wire Harnesses
We produce JST-style jumper wire harnesses for compact electronic devices, LED products, batteries, sensors, appliances and small equipment. Common requirements include small pitch connectors, reliable terminal crimping, accurate pin assignment and stable continuity performance.

3.Molex Jumper Wire Cable Assemblies
Yihetai supports Molex-style jumper wire cable assemblies for industrial electronics, power supply units, control systems and equipment wiring. We can provide single-row, dual-row, multi-pin and customized connector configurations based on your assembly drawing.

4.PCB Jumper Cable Assemblies
PCB jumper cable assemblies are used to connect PCBs, displays, control boards, sensors, switches, power modules and other internal components. Yihetai can manufacture PCB jumper cables with crimp terminals, soldered ends, IDC connectors, housing connectors, ring terminals or customized end treatments.

5.Flat Ribbon Jumper Cables
For applications that require multiple parallel conductors and neat routing, Yihetai can manufacture flat ribbon jumper cables, IDC ribbon cables and rainbow flat cables. These are commonly used in electronics, display modules, control boards and communication devices.

6.Custom Single Wire Jumpers
We produce single wire jumpers with stripped ends, tinned ends, ferrules, ring terminals, spade terminals, quick disconnect terminals, Faston terminals or customized terminal combinations. These are suitable for appliances, power systems, switch panels, control boxes and internal equipment wiring.

Key Features of our jumper wire

Custom lengths from 10cm to 2m+ and multi-wire configurations
Compatible with Dupont, JST, Molex, TE connectors
Wire gauges 18-30 AWG with PVC, silicone, or Teflon insulation
Stable signal transmission for data and low-voltage power
Precision crimping, soldering, and IDC assembly processes
Optional shielding, waterproof IP65 overmolding
High-flex for vibration-prone environments like robotics
100% continuity, pull-force, and electrical testing pre-shipment

Common Specifications of Custom Jumper Wires

Item	Common Options	Customizable Requirements
Pitch	1.0mm, 1.25mm, 1.5mm, 2.0mm, 2.54mm, 3.96mm	Can be customized according to connector series and PCB layout
Wire Gauge	AWG 32, 30, 28, 26, 24, 22, 20	Selected according to current, voltage, flexibility, and application space
Connector Type	Dupont, JST, Molex, IDC, PH, XH, VH, terminal housing	Equivalent or original connector brands can be used based on customer needs
Length	50mm, 100mm, 150mm, 200mm, 300mm, 500mm	Any custom length available according to assembly space
Wire Color	Red, black, yellow, blue, white, green, rainbow cable	Color coding can be customized for easy installation and maintenance
End Connection	Female-to-female, male-to-male, male-to-female, wire-to-board	Single-ended, double-ended, stripped, tinned, crimped, or soldered ends available
Application	PCB, breadboard, testing fixture, control board, LED module	Designed according to mechanical, electrical, and environmental requirements

Dupont vs JST vs Molex vs IDC vs PH/XH Jumper Wires

Connector Type	Typical Pitch	Main Features	Common Applications
Dupont	2.54mm	Easy to use, flexible, suitable for prototyping	Breadboard, Arduino, Raspberry Pi, testing
JST	1.0mm – 2.5mm	Compact size, stable wire-to-board connection	Battery pack, sensor, LED, small electronics
Molex	Various pitch options	Reliable performance, suitable for industrial use	Industrial control, automotive electronics, power supply
IDC	1.27mm / 2.54mm	Good for multi-pin flat cable connection	Control board, display, computer, signal transmission
PH / XH	2.0mm / 2.5mm	Common PCB connector solution	PCB board, charger, lighting, small motor, appliance

Custom Jumper Wire vs Ribbon Cable vs Wire Harness

Product Type	Best For	Structure	Typical Use
Custom Jumper Wire	Simple point-to-point connection	Single wires or small groups of wires with connectors	PCB connection, breadboard, module testing, internal electronics
Ribbon Cable	Multi-pin signal transmission in a flat layout	Parallel flat cable with IDC or other connectors	Display module, computer equipment, control board, signal wiring
Wire Harness	Complex electrical connection system	Multiple wires, branches, connectors, terminals, sleeves, labels	Automotive, industrial equipment, medical devices, appliances, machinery

Applications

Custom jumper wire cable assemblies provide reliable connections for a wide range of industries and applications.

Customization Options

At Yihetai, all jumper wire products can be customized according to customer requirements.

Custom Item	Available Options
Wire Type	Single wire, parallel wire, ribbon cable, multi-core cable
Conductor	Bare copper, tinned copper, stranded conductor, customized
Wire Gauge	28 AWG to 18 AWG or customized
Length	Customized according to installation space
Color	Standard or custom color coding
Connector	Dupont, JST, Molex, TE, Hirose, IDC, equivalent alternatives
Terminal	Crimp terminal, ferrule, ring terminal, tin-plated terminal, customized
Jacket Material	PVC, PE, XLPE, TPE, PTFE and other specified materials
Process	Cutting, stripping, crimping, soldering, ultrasonic welding, overmolding, labeling, bundling
Testing	Continuity, insulation resistance, hi-pot, pull force, visual and dimensional inspection

We can manufacture based on customer drawings, samples, BOM lists or application requirements.

Send us your drawing, sample or specification for a fast quotation.

Manufacturing Capability

Yihetai has more than 25 years of experience in custom wire harness and custom cable assembly manufacturing. Our factory is equipped with advanced processing equipment including automatic wire cutting machines, stripping machines, crimping machines, terminal insertion equipment, testing instruments and assembly lines for different jumper wire and harness projects.

We handle prototypes in 3-5 days, low-volume runs, and mass production up to 100K/month. Strict in-line QC from material incoming to final packing ensures reliability in our wiring harness factory.

JUMPER WIRE PRODUCTION PROCESS

Cutting → Crimping → Terminal Insertion (Housing) → Finished Assembly

Quality Assurance & Control

Our production system is managed under strict quality standards. Yihetai operates under ISO 9001 quality management, with UL certified wire capability and IATF 16949 experience for automotive-related wire harness projects. Each jumper wire assembly can be inspected for continuity, pinout, crimping quality, pull force and appearance before shipment.

Our quality control process includes:

Incoming materials inspection
Soldering quality inspection where required
Terminal insertion and locking position check
100% continuity testing
Short circuit and open circuit testing
Insulation resistance testing
Dimensional inspection according to drawing
Label, marking and packaging verification
Full traceability for production batches

Common Jumper Wire Problems We Help Customers Avoid

Wrong Pinout

Incorrect pin assignment can cause device failure, short circuit or assembly delay. Yihetai follows approved drawings and can perform pinout testing before shipment.

Poor Crimping

Unstable crimping may lead to loose terminals, high resistance or intermittent connection. We control crimping quality and can perform pull force testing according to requirements.

Unstable Connector Fit

Incorrect connector selection may cause poor mating, loose locking or difficult assembly. Yihetai can help confirm connector type, pitch, terminal and housing before production.

Incorrect Wire Length or Color Sequence

Wrong length or color order can slow down assembly and increase production mistakes. We manufacture according to approved samples, drawings or color sequence requirements.

Inconsistent Quality in Mass Production

For long-term production projects, repeatability is important. Yihetai supports stable process control, electrical testing and traceability according to customer requirements.

Why Choose Yihetai Jumper Wires

25+ years of cable and wire harness manufacturing experience

ISO 9001, UL and IATF 16949 based production system

In-house wire processing and harness assembly capability

Own wire and cable manufacturing support for better cost and lead time control

Flexible production for prototype, low-volume and mass production orders

Strong capability for both low-volume and mass production

Custom Jumper Wire Gallery

Frequently Asked Questions

Q1: Can you customize jumper wires according to our drawings or samples?

Yes. We can manufacture custom jumper wire products based on drawings, samples, BOM lists or application requirements.

Q2: What connector brands can you support for jumper wire assemblies?

We can support Dupont, JST, Molex, TE, Hirose and many other connector systems, as well as compatible replacement connectors.

Q3: What is your MOQ for custom jumper wire?

MOQ depends on wire type, connector type and process complexity. We support both prototype orders and volume production. Please send us your specification for evaluation.

Q4: Do you test all jumper wire assemblies before shipment?

Yes. Our products normally go through 100% continuity and basic electrical testing before shipment. Additional tests can also be arranged based on project requirements.

Q5: Can you help if we only have an application idea but no finished drawing?

Yes. Our team can assist with connector confirmation, wire selection, structure suggestions and sample development based on your application needs.

Can you help replace a standard jumper wire with an OEM production-ready cable assembly?

Yes. Many customers start with standard jumper wires during development and later need a cleaner, safer and more reliable OEM assembly for production. Yihetai can help optimize the structure, connector selection, wire routing and testing requirements.

Need a custom jumper wire for your application?

Send us your drawing, sample, connector specification, wire gauge, cable length, quantity and application details. Yihetai will evaluate your project and provide a practical custom wiring solution for your equipment, from prototype to mass production.