Custom Lighting Wire Harnesses & Cable Assemblies
Certified IATF 16949 & ISO 13485 manufacturer providing high-reliability connectivity solutions exclusively for Automotive, Medical, and Industrial lighting systems.
Our Clients
Industry Applications
Our high-reliability lighting wire harnesses are engineered to endure the rigorous environmental and safety demands of the modern industrial sector. Leveraging our IATF 16949 and ISO 13485 certified manufacturing processes in China, we provide mission-critical connectivity across these specialized lighting sectors:
Automotive & Vehicle Lighting Systems
Medical & Surgical Illumination
Industrial & Outdoor Waterproof Lighting
Lighting Wire Harness & Cable Assembly Selection Guide
Selecting the right lighting wire harness depends on fixture design, electrical requirements, connector configuration, cable routing, and installation conditions. Use this guide to identify key requirements for your custom lighting cable assembly project.
| Lighting Application | Key Selection Requirements | Technical Considerations |
|---|---|---|
| LED Lighting Fixtures | Reliable power and signal connections, compact routing, secure terminals, and compatibility with the lighting fixture design. | Wire gauge, connector type, conductor configuration, cable length, terminal selection, and routing space within the fixture. |
| Industrial Lighting Systems | Stable electrical connections for lighting equipment used in manufacturing, warehouses, workshops, and industrial facilities. | Cable construction, connector retention, mechanical protection, routing requirements, and compatibility with the equipment enclosure. |
| Commercial & Architectural Lighting | Clean cable routing, compact assemblies, reliable connections, and flexible configurations for commercial and architectural fixtures. | Assembly dimensions, cable length, connector configuration, branch structure, insulation selection, and installation requirements. |
| Outdoor Lighting Equipment | Cable assemblies designed around outdoor installation conditions, with appropriate protection against moisture, temperature changes, and mechanical exposure. | Connector sealing, cable jacket selection, strain relief, protective sleeving, routing, and environmental requirements. |
| Automotive Lighting | Compact and securely routed cable assemblies for vehicle lighting, including lighting modules, lamps, and related electrical systems. | Connector compatibility, terminal selection, vibration considerations, cable routing, branch configuration, and electrical specifications. |
| Lighting Controls & Power Systems | Reliable connections between lighting fixtures, controllers, power supplies, drivers, sensors, and control components. | Power and signal separation, conductor configuration, connector selection, cable length, pin assignment, and assembly testing. |
Connector Options
Selects the right connector based on your performance requirements and environmental conditions.
Mini-Fit Jr.™ Connectors
Supporting a high-current capacity of up to 13A per circuit with a secure TPA locking mechanism. These are the preferred choice for reliable power distribution in vibration-heavy environments, such as automotive systems, industrial machinery, and high-power medical equipment.
KK™ Series Connectors
A cost-effective wire-to-board solution with a standard pitch. Frequently utilized in auxiliary control boards for consumer electronics, household appliances, and diverse industrial control modules.
Micro-Fit 3.0™ Connectors
Featuring a compact 3.0mm pitch to solve space-constraint challenges. Their polarized, foolproof design eliminates the risk of mis-mating in high-density control systems, robotics, and telecommunications infrastructure.
MX150™ Sealed Connectors
Engineered with an IP67 rating to provide a complete seal against moisture ingress and dust contamination. Essential for marine electronics, automotive engine compartments, and outdoor industrial equipment requiring exposure to harsh fluids and weather.
FCT D-sub Connectors
Providing high-durability, interference-resistant connectivity for complex user interfaces, laboratory equipment, and aerospace communication systems.
Nano-Fit™ Connectors
Delivering robust electrical performance in an ultra-compact 2.50mm pitch. These are ideal for Internet of Things (IoT) sensors, wearable technology, and compact electronics where every millimeter of PCB space is critical.
SL™ Modular Connectors
Utilizing advanced shielding and locking technology to maintain superior signal integrity in high-speed data applications. They serve as the backbone for data centers, industrial automation networks, and smart infrastructure.
Why Choose LEX?
Empowering global industry leaders with custom-engineered connectivity solutions, anchored by uncompromising quality and rigorous international standards.
Dual-Standard Quality Excellence
We operate under both IATF 16949 (Automotive) and ISO 13485 (Medical) certifications. This dual-standard approach applies the most rigorous traceability and zero-defect protocols to every OEM project, ensuring premium quality regardless of your industry.
Professional DFM Engineering Support
Our team provides expert Design for Manufacturing (DFM) reviews to optimize your schematics. We bridge the gap between complex prototypes and efficient mass production, helping you reduce material waste and avoid costly design revisions.
Advanced Precision Automation
With a 5,000㎡ modern facility, we utilize integrated automatic crimping, housing assembly, and ultrasonic welding. These high-precision technologies ensure 100% consistency and superior electrical integrity for high-volume orders.
Texas-Based Technical Support
Experience the ease of local communication. Our dedicated sales and engineering office in Texas, USA, provides real-time technical assistance and rapid design iterations during your business hours, eliminating the challenges of time zones.
High-Mix, Flexible Manufacturing
We excel at managing the entire product lifecycle, from low-volume, high-complexity (HMLV) prototypes to large-scale mass production. Our flexible lines allow you to scale rapidly without sacrificing quality or delivery speed.
Global Compliance & Market Entry
Every assembly is engineered to meet UL, CSA, RoHS, and REACH standards. We handle the complex compliance requirements of the global market, ensuring your products are ready for immediate international distribution.
Quality Management & Certifications
LEX applies structured quality management systems, controlled manufacturing processes, and inspection procedures to ensure consistent performance and reliable quality for custom wire harnesses and cable assemblies across multiple industries.
IATF 16949:2016
Automotive quality management standard supporting structured production processes and customer-specific requirements.
ISO 13485
Quality management system supporting controlled manufacturing processes, documentation control, and consistent product quality management.
Production Quality Control
What Our Customers Are Saying
From rapid prototyping to large-scale production, we’ve built lasting partnerships based on manufacturing excellence and transparent communication. Here is what our global partners across diverse industries have to say about their experience working with us.
Frequently Asked Questions
1. How does LEX ensure IATF 16949 compliance for custom automotive lighting harnesses?
As a certified manufacturer, we apply the rigorous IATF 16949:2016 quality management system to every stage of our automotive production. Every lighting harness is engineered in our China-based facility to withstand extreme road vibrations and thermal fluctuations typical of vehicle environments. To guarantee mission-critical reliability, we utilize an advanced laboratory equipped with terminal cross-section analyzers and CCD digital microscopes to ensure zero-defect performance before delivery.
2. Does LEX provide ISO 13485 certified wiring for medical surgical lighting systems?
Yes, our manufacturing processes achieved ISO 13485 certification in 2023, specifically for medical-grade cable assemblies. We design and produce high-precision wiring for shadow-free surgical lamps, wall-mounted medical lights, and complex diagnostic equipment. These products are manufactured in a controlled environment to ensure high safety standards, stable power delivery, and essential electromagnetic compatibility for critical clinical settings.
3. Can LEX produce high-performance waterproof solutions for outdoor and industrial lighting?
Absolutely. We specialize in ruggedized connectivity for industrial routers, tunnel lighting, and smart infrastructure that require superior environmental protection. By utilizing professional UV glue curing and ultrasonic welding technologies, we achieve high-level waterproofing (IP67/IP68) and UV resistance. Our expertise as a National “Specialized and Sophisticated” SME allows us to design high-durability solutions that remain stable in harsh outdoor climates.
4. What are the advantages of LEX’s global service model for international B2B clients?
LEX offers a unique “Global Presence” strategy designed to eliminate communication barriers and supply chain risks. While our 5,000+ $m^2$ high-capacity manufacturing base is located in China, we maintain a dedicated sales and technical support office in Texas, USA. This model allows international clients to benefit from cost-effective, high-volume production in China while receiving localized, real-time technical consulting and after-sales service from our US-based team.
5. Is LEX a verified supplier for industry-leading brands like CATL and King Long?
LEX has established itself as a trusted Tier 1 and Tier 2 supplier through a proven track record with global industry giants. We are a strategic partner for CATL (New Energy), King Long (Automotive), and Jomoo (Smart Systems), providing them with mission-critical connectivity solutions. This experience with major manufacturers demonstrates our ability to meet the strict auditing requirements and high-volume production demands of the world’s leading technology and vehicle brands.