Design Services from Custom Wire and Cable Manufacturers

Design Services from Custom Wire and Cable Manufacturers

New products or pieces of machinery often have unique, specific requirements that can’t be met by stock cable

When developing a new product, the last thing you should be worrying about is whether there’s an existing cable that meets all the requirements for performance, durability, and price. The reality is that there may not be an existing solution that will meet all your requirements at a reasonable price point. And while your engineers may know what your cable needs to do, they most likely lack the experience with different conductors, jacketing materials, fillers, and insulations required to design a cable from scratch. Custom wire and cable manufacturers can provide a level of expertise in the area of electrical engineering that can save time and cost while developing the right cable for your application.

Designing a custom cable can be a challenging process, but a reputable cable and wire manufacturer acts as a partner every step of the way. They will walk you through the process to ensure that they are using the appropriate materials for your precise requirements. In many cases, they can even produce a prototype that allows you to test the cable on your product.

Thorough Consultations Make for Great Designs

The best way to ensure your custom cable meets all of your product’s requirements is to share as much information with your wire and cable manufacturer as possible. The first step in this process is to meet with their engineering team to share all of the specifications, as well as any applicable drawings. Don’t forget to make sure your drawings are created in a common format that can be easily accessed by the manufacturer. This will save both time and frustration for both parties.

As the next step, the manufacturer’s electrical engineering team will review your product’s specifications to ensure they have the capabilities to produce the type of cable you need on your requested timeline. It may be that they do not have the equipment or facilities to produce your cable. At this point, their team should be able to give you an idea of why they are not able to meet your specifications, whether the job requirements are realistic, and possibly make recommendations on how to feasibly produce the cable.

Collaborating with Wire and Cable Manufacturers on a Successful Cable Solution

Wire and cable manufacturers are the experts on customized cabling solutions, but you are the expert on your product. They will continue to hold conversations with you throughout the design process regarding voltage ratings, electrical tolerance, environmental parameters, and flexibility to ensure they choose a conductor material that performs as expected.

Further conversations about the cable’s function and expected environmental conditions will inform recommendations about insulating and jacketing materials. They may ask questions like:

  • Does the cable need to withstand high temperatures?
  • Does it require extra protection, like metal armoring?
  • Are there concerns about signal interference?
  • Does it need to meet spec standards like, UL, CSA, CE, or Mil-Spec?

Keeping Communication Open

Open communication is the key to ensuring positive relationships with wire and cable manufacturers. Designing a custom cable can be a complicated process, but if you provide their team with as much information as possible, it doesn’t have to be frustrating. And don’t forget to speak up if you need help. Experienced engineers, like the team at Meridian Cable, are always happy to answer your questions.