Where e-bike Wires Come From???

So often many e-bike OEM’s focus on the components but often forget about the wires and connectors. Most component failures of OEM e-bikes are due to bad or weak connections and/ or water moisture.

I had the luxury of touring a wire factory with a new focus on e-bike water tight connectors for signal cables. Some of the new designs feature quick release cabling for; brake, throttle, and display. The composition consists of audio style, gold covered, 3.5mm -5V headphone jacks. Junction molded “Y connectors” ensure a clean and tidy professional look. These actually are very time tested, cheap to implement into a design, and are surprisingly perfect for this this application. Available in any color under the sun (even two tone) if the minimum is worthy.

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Custom molded QR e-bike wire harness using audio technology
SAMSUNG
Molding machine for custom wire ends

Some other exciting advancements are nylon cable braiding right onto the cable itself to protect the inner PVC/ copper core and add rigidity. This is available in any single color or 2 tone.

SAMSUNG
Two tone nylon braiding wrap with 2 tone connector sample

The nylon braiding looks clean and helps add an additional layer of chaffing resistance.

SAMSUNG
Nylon braiding wrap in silver/ grey color

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