Expertise Matters When Designing A Custom Cable Assembly

Expertise Matters When Designing A Custom Cable Assembly

Balance longevity, performance, and price with a custom cable assembly designed with the help of experienced engineers.

Each custom cable assembly project comes with a unique set of requirements that calls for specific types of components for the best performance in a given situation. For example, a cable with the appropriate gauge for conducting electricity that is jacketed with a material that can’t withstand the environment will fail much sooner than it should even though it might meet requirements for price and performance.

With the many options available for conductors, insulations, fillers, and jacketing, a thorough working knowledge of which components offer the appropriate results for a given set of requirements is key to manufacturing a custom cable assembly that meets your needs at an appropriate price point. That kind of knowledge comes from a strong background that includes engineering and manufacturing custom cable assembly solutions for a variety of applications in a wide range of industries.

When reviewing recommendations from a custom cable manufacturer, it is essential to pay attention to a few key areas:

Conductor Gauge & Stranding Sizes

The gauge of a conductor impacts cost as well as how well electricity or signal flows through the wiring. An experienced engineer carefully considers how the cable will be used, as well as the voltage or signal type, and even the required length to determine the best gauge. While a larger gauge can reduce resistance and energy costs, a large gauge has a few drawbacks. The first of these is that larger gauges tend to be more expensive to produce. If your product does not require a larger gauge, you could end up paying more than necessary to produce your custom cable with no real additional benefits.

While solid conductors can be inexpensive, stranded conductors offer additional flexibility to the finished cable. By working with stranding sizes that range from 0.002” to 0.023” in a variety of materials, an engineer is able to recommend options that offer the conductivity and flexibility that meet the requirements of your project.

Insulation & Fillers

When we talk about insulation in a custom cable assembly, we are referring to a non-conductive material that is used to prevent energy leakage. Insulation also helps protect the wire from heat and moisture. Insulations can be made from plastics, fluoropolymers, and rubbers. Understanding the characteristics of each of these insulating materials is vital to producing a finished product that functions in a safe and efficient fashion. For example, some plastic insulations are inexpensive and have very good mechanical properties for many applications, but can emit a toxic halogens, making them inappropriate for use in some custom cable assemblies.

Fillers – like cotton, nylon, kevlar, PVC, and fleece – are used to ensure optimum performance in a custom cable. They have a variety of uses in custom cable assembly design, including reducing heat and friction as well as helping the cable maintain its shape.

Wraps, Shields, & Jacket Materials

Finally, choosing the appropriate wraps, shields, and jacket materials protects the conductors from interference, friction, and environmental conditions. The application, environment, and installation process can all be factors in what materials should be used to create your custom cable. There are a variety of plastics, rubbers, and fluoropolymers with differing resistance to heat, cold, moisture, and abrasion. With so many materials available, the knowledge and experience of your custom cable manufacturer can mean the difference between a well-performing cable at a reasonable price and an unnecessarily expensive or poorly performing product.