Conductor Gauges for Custom Design Cables

Conductor Gauges for Custom Design Cables

The right gauge conductors are key to making your custom design cables as effective as possible.

It’s no secret that creating custom design cables is the best way to ensure your product or equipment meets all of your specifications. Because the conductor gauge directly affects the flow of electricity or signal through the final product, the choice you make is extremely important. Choosing the wrong gauge can result in a less efficient cable that might lead to unnecessary costs. A reputable custom cable manufacturer will help you make the right choice and get the most successful outcome.

Cable Conductor Types

There are two main types of wire: solid and stranded. Solid conductors are a single, solid strand, usually made of copper. Stranded conductors are made up of smaller strands of copper that are twisted together to create a larger conductor. The main difference is that a stranded conductor is better able to withstand bending than a solid conductor. Additionally, solid conductors are less expensive to produce than stranded.

Why Size Counts with Custom Design Cables

custom design cable

For both types, the overall size of the conductor affects the flow of signal and electricity. Signal or electricity flows through larger gauge conductors more easily than it does smaller gauges. We refer to how easily the signal flows through the conductor as resistance. A wire with a conductor gauge that is too small is not providing the right amount of signal to the equipment it is powering. This could result in the equipment not functioning as it should. A too-small conductor gauge could also cause the wire to overheat, which may cause it to fail.

So…Larger Gauges Are Better?

While working with a larger conductor gauge seems like the safest bet, it’s not always the best option for your project. Larger gauges are able to accommodate more current, but they can be more expensive than all but the smallest gauges. In the end, the best gauge for your project is the one that closely matches your equipment specifications. Having an in-depth discussion with your cable manufacturer’s design team about the needs of your product is the most effective way to make sure you end up with a custom cable that functions as expected.

Gauge & Wire Length

When determining the gauge of conductors for custom design cables, the circumference isn’t the only consideration. The final length of the wire also affects the amount of resistance the current experiences. The longer the wire the more resistance there is, which weakens the signal. For longer cables, it may be necessary to use a larger gauge to counteract the resistance caused by the length.

Conclusion

Choosing the right gauge can be a complex process that includes a thorough understanding of the final cable’s uses, length, voltage, and signal type, as well as many other considerations. Working with a cable manufacturer you trust can make all the difference to the success of the final product. The Meridian Cable team has extensive experience with a wide range of custom cable design projects. When you are ready to discuss your next custom cable, please contact us. We look forward to talking with you.