Custom Wire, Cable and Assembly Solutions Built Smarter, Delivered Faster

We do not just build what you ask for, we collaborate to build what you need for today and innovate with you to stay ahead of your competition.

Who We Are

Mercury Wire is a U.S.-based engineering and manufacturing partner that designs and builds custom wire, cable, and assembly solutions for industrial, medical, defense, underwater, robotics, and other demanding applications.

• Trusted custom wire and cable manufacturer since 1967, based in Spencer, Massachusetts, serving customers nationwide and globally.

• One dedicated value stream team owns your project from design through delivery, eliminating handoffs and delays.

• We operate on a people‑first, lean, continuous‑improvement culture that prioritizes value and velocity for our customers.

Our Vision

To be the most trusted partner in custom wire, cable, and assembly manufacturing, helping customers succeed through innovation, collaboration, and shared growth. We are redefining how custom cables and assemblies are designed and delivered by building a more human, responsive model for manufacturing.

• We are redefining how custom cables and assemblies are designed and delivered by building a more human, responsive model for manufacturing.

• Our value stream teams own projects end-to-end, eliminating silos for faster decisions and seamless integration.

• Through lean processes and continuous improvement, we accelerate value velocity while honoring people, place, and prosperity.

Our Mission

We transform unique customer needs into reality through custom‑engineered wire, cable, and assembly solutions, delivered with precision, speed, and genuine partnership.

• Collaborative concept exploration uncovers real-world application needs beyond specifications.

• Rapid prototyping with agile decisions made by the build team, plus value stream ownership from start to finish.

• DIVE Process ensures design optimization, smart inventory, seamless value stream integration, and execution excellence.

Our Process

Discover

You bring us your application, performance targets, and constraints; our engineers “go see” and understand the real‑world problem, not just a spec sheet.

Design & Prototype

We collaborate on custom designs, rapidly prototype in‑house, and refine for manufacturability and performance.

Build & Scale

Dedicated value stream teams manufacture the cable and assemblies under one roof for consistent quality and faster lead times.

Deliver & Support

Kanban inventory, flexible production, and direct access to the team that built your product keep your operations moving.

Have An Existing Design?

Upload the details today using our Request Quote form for a fast turnaround.

Our Services & Capabilites

We do more than make cables. We create custom-engineered solutions that fit your application perfectly.

Custom Cable

When performance matters, standard cables are not enough. Mercury Wire designs and manufactures engineered cables built to your exact requirements. Our team focuses on the process, selecting the right materials, structure, and construction to deliver consistent and reliable performance for your application.

Assembly

We build more than cables. We build complete connectivity solutions.
Our assembly services combine precision craftsmanship with lean manufacturing to ensure every connection, crimp, and termination meets specification and passes rigorous testing. From concept to production, you work directly with the people who build your product.

Custom Engineering and Prototyping

Need to move fast without sacrificing precision? Our engineering team collaborates with you to refine designs, improve manufacturability, and accelerate prototypes into production. We focus on performance, repeatability, and cost efficiency, helping you get to market with confidence.

Our partnership with Mercury Wire transformed our plasma cutter cables, improving flexibility, durability, and visual appeal while ensuring consistent, repeatable quality. The result is a more reliable product and a better experience for every customer.

Why Mercury Wire for Custom Wire Cable and Assembly Solutions?

Custom Solutions

Every cable is engineered for your application using the right materials, structure, and process to deliver consistent performance and reliability.

Scalable Production

Our lean manufacturing methods allow you to move quickly from prototype to production, helping you reach the market faster without sacrificing quality.

Inventory Management

Through Kanban and pull-based systems, we keep your supply chain steady, reduce risk, and ensure your production line never stops.

Personalized Service

We are large enough to meet demand and small enough to stay personal. When you call, you speak directly with people who know your project and care about its success.

hand testing cables close up

close up of multiple wires in pish rod machine

custom push rod cable wire twisting

push cable worker in manufacturing setting

working in manufacturing pulling wire

Durability and Flexibility Are Key To Successful Custom Cable, Wire And Assembly Solutions

Mercury Wire partnered with a global inspection company to solve repeated cable failures in harsh utility environments. Our team designed a high-performance, waterproof cable using advanced materials and a dedicated production process that increased reliability, reduced downtime, and improved overall performance.

Client Testimonials

"Mercury Wire’s expertise and commitment completely transformed our cable assemblies. They helped reduce field failures, cut warranty costs, and deliver a more durable and reliable solution. Their team combined strong materials, thoughtful testing, and a deep understanding of our challenges to improve product performance and strengthen customer satisfaction."

Leading Manufacturer of Analytical Instrumentation

“Mercury Wire’s innovative approach transformed our plasma cutting leads, improving durability, simplifying assembly, and elevating product performance. Their ability to understand our needs and streamline production has made them a trusted partner, helping us maintain product excellence and dependable global delivery.”

Leader in Plasma Cutting Technology

“Mercury Wire’s custom wire line has transformed our supply chain by improving efficiency, increasing capacity, and strengthening communication. Their dedication to building a tailored production model has created a scalable solution that delivers consistent quality, flexibility, and uninterrupted product flow. We now have a manufacturing partner who truly operates as an extension of our team.”

Key Customer Benefiting from Mercury Wire’s Custom Line

Explore More Case Studies

Enhancing Assembly Efficiency Through Upstream Value

Enhancing Assembly Efficiency through Strategic Outsourcing About the Company Mercury Wire partners with customers to improve operational efficiency through strategic

Durability and Flexibility is Key

Mercury Wire partnered with a global leader in advanced inspection solutions to address challenges with their previous push cables, which

Custom Cables for Plasma Cutter Manufacturer

Discover how an industry-leading plasma and water jet cutting system manufacturer overcame critical challenges in cable performance and quality through

New Custom Wire Line

Discover how Mercury Wire transformed its operations with a dedicated custom wire line, significantly boosting efficiency, capacity, and customer satisfaction

Scaling Innovation to Meet Demand

Explore how Mercury Wire partnered with a leading manufacturer of light-based aesthetic and medical treatment systems to meet surging market

Creating Robust Industrial Solutions

Discover how Mercury Wire partnered with a leader in plasma cutting technology to enhance the durability and efficiency of their

Increasing Reliability and Performance

Learn how Mercury Wire tackled the challenge of failing cable assemblies for a leading manufacturer of water analysis instruments

Proudly Manufacturing In The USA Since 1967

Trusted By

Trusted by leading medical, industrial, defense, underwater, robotics, environmental, specialty lighting, and engineering manufacturers who rely on Mercury Wire for precision, reliability, and partnership in every connection.

Our Blog

Want real-world insights into custom wire cable and assembly solutions? Explore our blog to learn how custom solutions make a measurable impact.

Two people discussing in a factory

Investing in People and Progress

Mercury Wire’s Industry 4.0 Vision When a manufacturer truly develops its people, it

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