Custom Cable Assemblies with Standard Cables

Custom Cable Assemblies with Standard Cables

When designing custom cable assemblies for your product, it’s not always necessary to start from scratch.

Custom cable assemblies are designed and extruded for products or equipment when an existing cable does not meet the needs of the application. While stock cable can be inexpensive and easy to source, it doesn’t make sense if it simply doesn’t do the job required or is not as durable as it needs to be to withstand environmental conditions. In many cases, custom cables are a great way to make sure all your needs and specifications are met.

Cost is always a consideration whether you are dealing with custom or stock cable. Many perceive that “custom” means a higher price tag, but this doesn’t have to be the case. There are circumstances when a custom cable can even save money. For example:

  • Low Durability – A stock cable that doesn’t quite offer the durability for your application is going to need to be replaced more often. A custom cable more suited to the requirements and environment would need to be replaced less frequently.
  • Many Cables for One Piece of Equipment – One custom cable that meets all your needs is easier to install, maintain, and replace than multiple stock cables.
  • More Cable than You Need – Using stock cables means you sometimes have to pay for a more expensive option than you actually need. A custom cable eliminates that need because it is designed to meet the specifications of your equipment.
  • Creating a Cable from the Ground Up – There are circumstances when incorporating an off-the-shelf cable into a custom cable assembly saves time and money.

Making Smart Design Choices with Stock Cable

Commissioning a custom cable doesn’t mean you have to start from scratch by designing a completely new cable. If a stock cable is nearly perfect for your application, it’s possible to make some changes with a design based on the existing cable. These changes could include adding a tougher jacketing material or reproducing the cable with more flexibility or a different gauge that is not currently available.   

custom cable assemblies with black jacketing

Depending on the specifications of your product or equipment, you may need a custom cable assembly that combines multiple cables into one to save space. By combining these cables, the engineer can take advantage of different gauges and cable types – which may include stock cables – to create a streamlined solution that is tailored to your needs and specifications.

Talking with an Expert Wire & Cable Manufacturer

Off-the-shelf cables can be a great choice if there’s an existing model that matches the specifications for your product or equipment that is able to hold up to the environment where it will be used. But if a stock cable doesn’t meet your needs or is only “close enough,” talking to a wire and cable manufacturer might be the logical next step. During your initial discussion, make sure you clearly communicate how the finished cable needs to perform. If you are currently using an existing cable, share any frustrations or limitations you are experiencing. This will allow the engineering team to gain a full understanding of whether incorporating an off-the-shelf cable into your custom cable design makes sense.

An experienced manufacturer of custom cable assemblies, like Meridian Cable, can make recommendations that address any issues you are having with stock cables. They are also able to help you make the best choices when considering incorporating existing cables into your custom solution.