A cable assembly manufacturer has many options available that can help you stay in budget and get a custom cable that is right for your situation.
Having an unlimited budget to work with when designing a custom cord might seem like the best way to get the perfect end product, but that type of situation is rare. In most cases, budget is a concern. The good news is your cable assembly manufacturer should be able to help you balance the cable’s functionality with cost.
Good Communication Saves Money
This may seem like common sense, but make sure you are sharing as much information with your cable assembly manufacturer as possible in the planning and design stages of your project. Having clear specifications about how and in what environment the finished product will function gives the design team a thorough understanding at the outset. This can translate to a cable assembly that meets the needs of the equipment and environment with fewer revisions or surprises late in the project.
Talk Materials with Your Cable Assembly Manufacturer
Armed with complete technical specifications and a good understanding of the environment where a finished cable assembly will function, the design team is able to select the optimum materials to create a solution that operates as expected. At its most basic, a cable is made up of a conductor, connectors, jacketing, and insulation. Each can offer an opportunity for cost savings with some careful thought.
Obviously, the conductor material should be selected based on the type of signal and how long the cable is expected to be in use. However, with so many options when it comes to size, material, and plating, a cable assembly manufacturer can make recommendations that address cost concerns without compromising on functionality. For example: In many cases, a smaller conductor is less expensive. Choosing the smallest conductor that will transmit the signal or power allows you to get the functionality you need without the unnecessary expense of a larger conductor. Though, in some cases, a smaller conductor is actually more expensive to produce, so it’s doubly important to discuss options with your cable’s design team.
All cable assemblies connect to some sort of equipment or power/signal source. Because the section of cable that leads to the connector is a common point of failure due to stresses, it’s important to select the right type of connector for the job. While an overmolded cable offers more durability in many cases, it may make more sense to use a connector that can be repaired by a technician. Understanding the needs of your finished product allows you and your cable assembly manufacturer to make the right decision before producing a cable that doesn’t fit your needs.
Jacketing & Insulation
The environment where a cable assembly will be used often dictates what type of jacketing material or insulation is used in the finished product. Different materials are more suitable for cables that are exposed to extreme heat or cold, moisture, or stresses. More expensive materials for jacketing aren’t automatically better for every environment. In many cases, choosing a more costly material that is unsuited for the environment can be a waste of money and compromise the function or service like of the cable.
Good planning, open communication, and thoughtful selection of materials is the great way to save costs when creating a custom cable with a cable assembly manufacturer. If you are ready to talk about your next custom cable project, contact the team at Meridian Cable. We’d love to discuss your options.