Connector to individual wire ends
A connector at one end with individual leads at the other. Define each lead length and the required wire-end treatment.
Custom cable assemblies
Custom Discrete Wire Cable Assemblies
Individual insulated wires assembled with the connector or terminal ends your project requires. LDZY builds custom discrete wire cable assemblies from drawings, physical samples or connection requirements, with electrical testing on every completed assembly.
Explore discrete-wire configurations
Connector-to-connector wiring, separate wire ends and terminal-ended leads. These photographs show assembly styles; specifications are reviewed for your required configuration.
Connector-to-connector wiring
Individual wires between two connector housings. Specify the end-to-end connection map and connector orientation.
Connector and fork-terminal ends
Connector leads with fork-terminal ends. Define the wire and terminal requirements for each connection.
Customize the complete assembly
Specify the wires, connection ends and layout together. We confirm the construction for your project before sampling.
| Item | What to specify | Detail to confirm |
|---|---|---|
| Wire specification | Wire gauge, insulation material, colors and any required wire specification. | Wire specifications are reviewed for your application and confirmed in the quotation. |
| Connection ends | Connector or terminal required at each end, contact count and mating reference. | Identify each end separately, including any wires that remain unterminated. |
| Pinout and orientation | A connection map and the viewing direction for each connector. | Wire color alone does not define the required pin-to-pin connection. |
| Lengths and layout | Individual wire lengths, measurement reference points and any branch positions. | Mark where each length starts and ends, including any required tolerance. |
| Protection and identification | Any sleeving, heat shrink, grouping or label requirements. | Include these requirements in the drawing so the proposed construction can be reviewed. |
From drawing or sample to production
A clear confirmation process for the assembly you need.
Send a drawing, sample or requirements
With a drawing, we make samples to your drawing. With a physical sample, we prepare a drawing for confirmation before sampling. If you do not have a drawing, we can help prepare one from your requirements.
Review the proposed assembly
Confirm the wire specifications, connection map, lengths and quantities. Identify any open details so they can be resolved before samples are made.
Approve the sample
Review the sample against the agreed drawing and connection requirements. Samples are generally provided free of charge.
Place the production order
The typical minimum production order is 500 assemblies. Production follows the confirmed drawing and approved sample requirements.
Sampling and tooling
Samples are generally free. We do not charge crimp-tooling or fixture fees. The typical minimum production order is 500 assemblies.
Inside the LDZY wire-harness workshop
Our production floor brings wire processing and terminal-crimping workstations together for cable assembly work.
Fully automatic discrete wire cable assembly production
Watch the production process on LDZY’s fully automatic discrete-wire assembly line.
Electrical testing and production inspections
Every completed assembly is electrically tested. Periodic production checks cover additional workmanship and retention requirements.
100% electrical testing
- Continuity
- Short circuits
- Wiring errors against the confirmed connection map
Periodic production inspections
Appearance, terminal retention and other applicable items are checked periodically during production. These inspections are separate from the electrical testing performed on every assembly.
Include any required test methods, acceptance limits or inspection records in your inquiry.
Working from a drawing or BOM?
Share what you have, including any details that still need clarification. Start with these three project inputs.
Discuss Your Assembly- Drawing or BOMCurrent revision, wire specifications and required dimensions.
- Connection detailsConnector or terminal ends, pinout and orientation.
- QuantitiesSample and production quantities, with your requested timing.
Drawing and sample review
Define every lead and branch on the drawing
Give each wire end its own instruction
A connector-to-loose-lead assembly needs more than one overall length. Identify each lead by its connection point and specify its finished length, measurement reference and required end condition. Mark any leads that should remain unterminated; flag undecided details for review. Soldered ends, stripped and tinned leads, and multi-wire junctions are available, with the connection method and dimensions confirmed for the project.
Keep the layout and connection map separate
Wires can divide into separate routes without being electrically joined. Show physical routing separately from the end-to-end connection map. Identify each branch so its length, connector and wire instructions can be checked together.
Frequently asked questions
What is a discrete wire cable assembly?
It is an assembly made from individual insulated wires with defined connections at their ends. The wires may connect two housings, run from a connector to separate wire ends, or terminate in individual terminals.
Which wire gauges and insulation materials can I specify?
Send the wire gauge, insulation material, colors and any required wire specification. We configure the assembly around your requirements and confirm the specific construction during quotation.
Can you work from a physical sample?
Yes. We prepare a drawing from your sample for confirmation before making the assembly samples.
What if I do not have a drawing?
We can help prepare a drawing from your connection requirements. Include the endpoints, wire lengths, connection map and any available photographs or sketches.
Are samples and tooling free?
Samples are generally provided free of charge. We do not charge crimp-tooling or fixture fees.
What is the production MOQ?
The typical minimum production order is 500 assemblies. Include your required quantity with the inquiry.
What testing do you perform?
Every completed assembly is electrically tested for continuity, short circuits and wiring errors. Appearance and terminal retention are checked through periodic production inspections.
What should I send for a quotation?
Send your drawing, sample information or connection requirements, together with the sample quantity, production quantity and target schedule. Mark any details that still need clarification.
Discuss your discrete-wire assembly
Send your drawing, BOM or sample information with the quantities you need.