Author Archives: Justin Dennis

Discussing Jacketing Material with a Cable Assembly Manufacturer

Discussing Jacketing Material with a Cable Assembly Manufacturer

Do you really need to think about jacketing material when working with a cable assembly manufacturer to design a custom cable?

A cable assembly manufacturer can not only design a cable assembly, they can help you determine what type of jacketing material is appropriate for your application. While it might be tempting to overlook the jacketing on your cables, you could be missing out on some added value and functionality, including:

  • Enhanced Overall Flexibility
  • Better Flexibility in Low Temperatures
  • Quick Identification
  • Elastic Memory
  • Chemical Resistance
  • Resistance to Extreme Heat or Flame

As long as you think carefully about how and where the cable assembly will be used, you can address many of the environmental challenges that can affect the durability and safety of the finished cable by selecting the proper jacketing material.

Durable Cables in Challenging Environments

A cable’s outer jacketing is often the first line of defense against elements like heat, cold, moisture, UV rays, chemicals, and other substances that could affect the wire’s functionality. As with any custom wire, it’s important to consider all of the requirements for your environment and application. For example, jacketing made from PVC is a low-cost option that can handle the stresses of moderate daily use and withstand temperatures ranging up to 105 degrees Celsius. However, it would not be a good choice for a cable that must function in extreme heat or that is subject to heavy wear and tear – PU is a better choice for that type of environment.

Cables with Enhanced Safety Featuresred cable assembly

A custom cable assembly manufacturer can help you choose a jacketing material that is specifically designed to meet the needs of your equipment. This goes beyond the function and durability of the cable to the question of how safe it is. The jacketing of a cable assembly protects the conductor from stresses that would cause failure. However, you can also choose materials that are resistant to fluids and chemicals that could cause shorts or corrosion which could cause the wire to fail prematurely. In addition, jacketing material can be designed to be resistant to flame, which can help prevent the spread of fire.

Cable Aesthetics

How a cable looks might not be the top priority when discussing jacketing materials with a cable assembly manufacturer, but a cable’s appearance should not be overlooked. Altering the appearance of cable jacketing materials is more than just designing a cable that looks nice. Choosing matte or shiny finishes and specific colors can also be practical, because these features allow the finished cable to be quickly and easily identified. Cable jacketing can be produced in colors that match the appropriate equipment or signal whether it carries electricity or data. In addition, the cable’s texture can make it easier to grip which could be a desired feature in some environments.


When designing a cable assembly, selecting the right jacketing material for your application and environment can often be just as important as choosing the right conductor. A reputable cable assembly manufacturer can offer many options to ensure your finished cable meets your requirements for durability and functionality. Clearly communicating your environmental concerns along with technical requirements will result in a custom cable that offers you the performance and durability you expect. If you have any questions about jacketing materials, please feel free to contact the team at Meridian Cable.

Coil Cord Design: What Questions to Expect

Coil Cord Design: What Questions to Expect

Thinking through what you need before the coil cord design process starts can help you get the ideal cable for your equipment.

Custom coil cord design services allow you to get a final product that is a better match for your needs than an off-the shelf wire. But if you haven’t done some serious thinking about what you really need, you might not get the results you were looking for. Here are a few questions you can ask your team to get a coil cord that is truly customized to the requirements of your equipment.

In what environment will you be using the cords?

One of the first questions an engineer will ask during the coil cord design process is what environmental conditions the wire will need to withstand. Obviously, a cord used in a military or industrial environment has different requirements than one that would be used in a retail setting. Other questions could include: Will the cord be used inside or outside? Does it need to be able to withstand extreme heat or cold? Will the cord come into contact with moisture or oil? These are all conditions that can and should be taken into consideration when designing coil cords.

How long should the coil cords last?

A coil cord that lasts forever might seem like an ideal product, but if higher durability compromises function and/or makes it prohibitively expensive to produce it may not be worth it. In addition to durable jacketing material, there are other elements that can affect longevity. For example, choosing stranded wiring as a conductor can create a cord with a higher resistance to metal fatigue than a solid conductor. However, tinsel might be a better choice if you need flexibility but the finished wire can’t handle a high current capacity.

How dynamic are the coil cords during normal function?coil cord design

A coil cord can be designed with materials like steel, Kevlar, Spectra, or Teflon to make them virtually indestructible. That sounds great, but is that durability worth the added expense to produce for a cord that doesn’t require it? By clearly communicating your cord’s normal, everyday function, a coil cord design team can recommend materials that are the right balance of cost and physical properties for your equipment. A key question will be how many extension and retraction cycles the coil cord will experience in its life.


Custom coil cord design from a reputable cable manufacturer like Meridian Cable is a great way to get a cord that is perfectly tailored to your application. While there are many different elements to take into consideration when creating a custom coil cord, thinking through the questions above is a great way to prepare for initial discussions with the design team. When you are ready to discuss your project, please contact us. We look forward to hearing from you.

Custom Coil Cord 101

Custom Coil Cord 101

A custom coil cord is the ideal solution for a wide range of applications where space or flexibility are concerns.

A custom coil cord, also known as a curly cord or retractable cable, is probably most familiar as a part of a home or business telephone…and for good reason. With a non-mobile phone, it is important for the cord to accommodate the user’s movements while in use. But when not in use, it’s more convenient when the cord takes up less space. These same features are beneficial for use with many other types of equipment, from medical devices to surveillance systems.

What is a custom coil cord?

The basic shape is essentially the same with all coil cords. They have straight sections at each end with a curled section in between. The ability to stretch and retract is determined by the diameter of the curled section and the material used to create the cable. Because they are able to stretch and retract, they are more resilient and take up less space than conventional cables. 

Stock coiled cord is available, but if you are interested in designing a cable that is a perfect fit for your equipment, a custom solution might be the answer. With a custom coil cord, you are able to select the conductor, jacketing, and additional materials as you would with any other custom cable. However, you are also able to dictate other elements that determine how the finished product will perform.

Customizing a Coil Cord

The coiled section is the most common physical feature that is customized. Cable can be wound into coils from ¼ of an inch to 5 inches, depending on the desired length of the extended cord. But this isn’t the only feature that we pay attention to when designing a custom coil cord. black custom coil cord

The straight sections at each end of the cord are called tangents. Tangents are either perpendicular or axial, and should be taken into consideration when looking at functionality versus budget. For example, an axial tangent takes a little longer to manufacture, but it exits the coiled section of the cord along the centerline of the coil, which allows it to stretch along the same line as the rest of the cable.

Cycled vs. Stationary Coiled Cable

Not every custom coiled cable has to withstand the same stressors. The two main types of coiled cable are cycled and stationary. Stationary coiled cables are used to connected a device that is in a fixed location with one that moves. A cycled cable is used in applications where it must be extended and retracted continually without failing – think bar code scanners that are often used hundreds of thousands of times.


Custom coil cords are a great solution when you need a cable that saves space while being flexible and durable. While many of the benefits of designing a custom coil cable are the same as when you create a non-coiled cable, there are a few additional features to take into consideration. If you are looking for a partner with the knowledge and experience to help you navigate designing a custom coil cord, contact Meridian Cable. We’d love to talk with you about your project.

Safety Considerations for Custom Cable Assemblies

Safety Considerations for Custom Cable Assemblies

Safety should always be the top priority when creating custom cable assemblies.

Sourcing custom cable assemblies from a reputable manufacturer is the best way to ensure your equipment or product is free of safety issues. While there are situations when an off-the-shelf cable assembly makes sense for your budget and the cable’s application, it is essential to carefully consider how using an assembly that is not customized will affect the overall success of the project.

Any time you are dealing with electricity, safety is key. Faulty cable assemblies made from improper materials can cause equipment damage, which can lead to expensive repairs. In addition, you will experience lowered productivity while the damaged equipment is being repaired. That may be the best-case scenario. Low quality cable assemblies can cause bigger problems, like environmental harm and safety issues from toxic smoke or electrical fires.

Ask Questions

The best way to prevent these issues is to make sure you are using a custom cable assembly designed by a safety-focused cable manufacturer. But how can you know a manufacturer is focused on safety? One of the best ways is to be sure to ask about certifications as well as testing procedures when you are discussing your project. An honest conversation about how the manufacturer ensures a safe product can save you more than just headaches. It could prevent lawsuits or even serious injuries.

Safe Materials for Your Custom Cable Assemblies

When going through the design process, be sure to discuss materials that will be used in your custom cable assembly. Choosing the right gauge and material for the conductor is key for functionality and safety. However, making good decisions when it comes to insulation and jacketing can also be the difference between a safe custom cable assembly and one of questionable quality. While there are many components that could affect the safety of custom cable assemblies, talking about conductors, insulation, jacketing, connectors, and strain relief is a great start.


Copper is the most commonly used conductor, but that doesn’t mean that it’s the right material to use for your project. Because it is prone to corrosion, it is necessary to consider whether plating or copper alloys might be more appropriate choices. Another consideration is whether your equipment would be better served with a solid or stranded conductor.

Insulation & Jacketing

Clear industry standards exist for the appropriate insulation and jacketing to use in specific applications, so be clear about the conditions your finished cable will be operating under. Does the cable need to perform in extreme temperatures? Under heavy pressure? In wet environments? The answers to all of these questions will help your cable manufacturer choose the right materials.

Connectors & Strain Reliefcustom-cable-assemblies-connector

The terminal points of a cable can be common failure points due to the additional stresses in those areas. While the technical needs of the equipment often drives the choice of connector, additional strain relief can prevent termination failure.  If additional strain relief is needed, the cable assembly designer can add a transition point that alleviates some of the added stress.


Using custom cable assemblies is often the best way to build safe products or maintain safe equipment. When you are talking to a custom cable manufacturer, don’t be afraid to bring up safety. Engineers should be ready and able to discuss how they are ensuring a safe product.

If you are ready to talk about a new project, please get in touch with the team at Meridian Cable. We would love to hear from you.

Important Certifications for a Cable Assembly Manufacturer

Important Certifications for a Cable Assembly Manufacturer

Paying attention to a custom cable assembly manufacturer’s certifications is essential in today’s marketplace.

If you’ve recently been on the website of a cable assembly manufacturer, you have almost certainly noticed certifications listed in a prominent location. With so many options when it comes to certifications, it can be difficult to know what is important and, above all, reputable when reviewing manufacturers.

Obviously, different types of manufacturers should have certifications that are most applicable to their industries and products. There are many of these certifications that are nice to have, but not absolutely necessary, and you should evaluate these with your project and equipment needs in mind. However, if you are working with a cable assembly manufacturer, there are certifications from two organizations that are worth paying closer attention to.

ISO – International Organization for Standardization

The International Organization for Standardization is recognized around the world as an independent source of best practices for a wide range of industries. Seeing an ISO accreditation on a cable assembly manufacturer’s website signals that they are a credible organization that is committed to creating safe products of high quality.  ISO certification for cable assembly manufacturer

In an industry where product failure can be life-threatening, it’s vital you work with a manufacturer that takes your concerns about safety seriously. If you don’t see any mention of an ISO certification, it’s worth having a discussion about why not. There are also many types of ISO certifications, so it can be valuable to familiarize yourself with any specific accreditations you see.

UL – Underwriters Laboratories

You may be more familiar with UL from the stamp that appears on products like light bulbs and lamps that are meant to function using electricity. UL ratings like these can help consumers determine in what types of conditions the product is meant to perform. This can also be the case for custom cable assemblies. Like ISO, UL can be focused on ensuring the quality and safety of the end product. However, UL also offers certification of the manufacturing process to make sure a company is able to to produce safe products that meet standards.

Additional Certifications for a Cable Assembly Manufacturer

ISO and UL are well-known and offer certifications for a wide range of industries, processes, and products, but they aren’t the only options. If you see certifications you are unfamiliar with, don’t hesitate to ask about them. The team at your cable assembly manufacturer should be ready to discuss their reasonings behind pursuing specific accreditations. There are also industry-specific options (like AS9100 for aerospace) that may be appropriate for your project. Always make sure you follow up any questions you ask the manufacturer by doing your own research.


Certifications can be extremely valuable when you are evaluating a cable assembly manufacturer. They not only show a dedication to producing safe products and working environments, but also demonstrate a dedication to staying at the top of industry best practices by maintaining standards that are continually updated. With a little knowledge, you can use this information to make the best choice. When you are ready to talk about your next project, the Meridian Cable is happy to answer all your questions. Get in touch with us, today!

5 Uncommon Questions to Ask Wire Harness Manufacturers

5 Uncommon Questions to Ask Wire Harness Manufacturers

Knowing what to ask when talking to a wire harness manufacturer is key to choosing the right one.

Wire harness manufacturers come with a wide range of experience and specialized knowledge. However, finding the right organization is more than simply reviewing their credentials for a specific project. You also want to find a team that is a good fit with yours. With a few carefully chosen questions, you can build a partnership with a reliable manufacturer that lasts beyond one or two jobs.

Talking with Wire Harness Manufacturers

The process you go through when hiring a wire harness manufacturers has a lot in common with conducting interviews for employment. The information you need to ensure they can do the job is covered by obvious questions, like:

  • What industries do you serve?
  • What is your experience with my type of equipment?
  • What is your lead time on orders?
  • Are you able to produce small/large quantities?

You absolutely want to cover that information, but there are a few other questions you may not think to ask that can shed additional light on how your working relationship would be. These include:

Who is your ideal customer?

There is no perfect answer to this question. You can, however, learn a little bit about how the wire harness manufacturer’s team likes to work, what their communication style is, and whether their expectations for how closely you will work match with yours. It can serve as a conversation starter, so it might be useful to give some serious thought to what kind of customer you will be.

What do you consider your greatest success on a project?Wire Harness Manufacturers

Again, there isn’t a right answer for this question. There can be a wrong one, though. You don’t want to hear, “The cable worked.” That should be a given. Listen for tough challenges that were overcome. Ask for details. While they may not be able to give specifications, they should be able to talk about they how they worked through the problem.

Can you give references?

You should ask for references from every wire harness manufacturer you are serious about working with. While references are almost always handpicked to give the best possible impression of the manufacturer’s work, they should still be able to provide them. And you should contact those references. Make sure you talk about their experience working with the manufacturer and how the wire harnesses they produced perform.

Do you have one or two big clients that provide you with most of your work?

Answering yes to this question shouldn’t automatically rule out a contender for your project. However, it can imply that your project might not be as high of a priority for them. While this isn’t always the case, it is something you want to address before you get started.

Can you describe your testing and quality control process?

This question is less relationship based, but it’s vital that you understand how a wire harness manufacturer ensures the quality of the products they produce. It goes beyond ensuring the product works. Products that have gone through rigorous testing are just safer to use. It’s not an area where you want to cut corners.


Technical know-how and manufacturing capabilities are obvious areas to consider when talking to wire harness manufacturers, but that information doesn’t always tell the whole story. Asking a few questions during initial discussions can help you understand what a relationship with the company would be like. When you’re ready to discuss your next custom wire harness, please get in touch with the Meridian team. We’d love to hear about your project.

Assembled vs. Molded Cable Assembly: What You Need to Know

Assembled vs. Molded Cable Assembly: What You Need to Know

There are two main options when it comes to shells for terminal connectors on your custom cable: assembled and molded.

Choosing between a molded cable assembly and one that must be assembled in the field requires careful consideration to ensure you are making the right decision for your application. When designing a custom cable assembly, there are many options for conductors, insulating materials, jacketing, and so on. All of these choices can affect the performance and durability of the finished cable. However, even the most durable cable is most likely to fail at the terminal point. The process of cutting and fitting the cable with a connector can expose it to damage. Once the terminal is in place, it is frequently the section of cable that is subject to the most twisting, bending, and other stresses. Because of this, the selection of a connector is key to determining the overall success of the cable.

Assembled Cable

As you may have guessed from the name, assembled cables consist of multiple pieces that are put together manually in the field. Connectors can have plastic or metal shells, and in some applications are the only solution. However, when you are choosing between assembled and molded cable assemblies, there are a few important considerations:

  • Installation – Since cables and connectors are assembled in the field, the experience and knowledge of the technicians performing the installation is very important. Whether using in-house or outsourced personnel, you must ensure that they are properly installing and testing your cable assemblies to prevent failure due to improper installation.
  • Cost – Comparing costs for assembled and overmolded cable assemblies can be tricky. On one hand, assembled cables are less expensive to produce, but you must also factor in labor costs for installations which can add to the overall expense.
  • Repairs – Because these types of cable assemblies are made with multiple components, they can be disassembled for applications when it makes more sense to repair an existing cable assembly than replace it with a new one.

Molded Cable Assembly

Overmolded cable assemblies feature shells that have been created by heating a plastic or rubber material and injecting it into a mold. Because the products are custom-molded, even aesthetic elements like color can be chosen for a sleeker appearance or to help differentiate cables. Here are a few of the benefits of overmolded products:molded cable assembly

  • Customization – With the range of materials available when designing a molded cable assembly, you are able to produce a cable that is tailored to the specific environmental concerns of your equipment.
  • Fewer Installation Errors – Since no additional assembly is required, a molded cable assembly can be installed quickly with a simple process that minimizes the opportunity for human error.
  • Strength & Flexibility – Cables are subject to additional stresses where they exit the connectors. Overmolded components can be designed to offer additional flex and strain relief to create a cable that is more durable and less susceptible to premature failure.

Choosing between an assembled or overmolded cable assembly is an important decision that requires some careful consideration. Meridian Cable is able to produce cables with overmolded components in house, using a wide variety of materials to ensure your finished cable meets the needs of your equipment. If you’re ready to design an overmolded cable assembly, get in touch. We’d love to hear about your project!

Hiring a Cable Assembly Manufacturer: What to Think about First

Hiring a Cable Assembly Manufacturer: What to Think about First

So, you need a custom cable, but don’t know what to look for in a cable assembly manufacturer.

One cable assembly manufacturer is not necessarily the same as another. Each has specific capabilities and experience that make them the right choice for designing and manufacturing different types of cable. But how do you even begin the search if you don’t know what questions to ask or information to provide?

Over the years, Meridian’s engineers have come up with a method to quickly determine what kind of cable assembly a customer needs that could be helpful when you are given the task of finding a wire and cable manufacturer.

Determining the General Type of Cable

The Meridian team starts with the simple assumption that all cable assemblies carry power or signal from one end to the other. The first step we take is to find out which the assembly needs to carry, or both. Since we extrude our own cable, we can handle any of these scenarios, but there are some power or signal cables we can’t make. Determining that from the beginning is critical for us and should be for you as well.


Power, for the most part, is easy to determine. The more power a cable needs to deliver, the more conductive material it requires. For example, it’s easy to pass 1 amp of current through a 24 awg conductor that is 1 foot long. However, bad things can happen very quickly if you try passing 20 amps through a 24 awg conductor. We don’t make high power cables at Meridian. If the power transmission requirements are above about 40 amps, we are upfront with the customer about our capabilities. Since we’ve been around long enough to know which companies do extrude high power cables, we will happily share that information.

It should be noted that, with power, often all you need to know is the voltage and current. In many cases, customers don’t have this information, but they do know what is on either end of the needed assembly. Most times, we can make a rough determination of the voltage and current by knowing what devices the assembly is connecting. From there, the design can be narrowed significantly enough to get the process moving.


Signals, for the most part, are complicated. Sure it’s all data, but new ways of transferring data are created all the time. For example, think of your TV 10, 20, or 30 years ago. (Some of us here at Meridian are old enough to remember TVs 30 years ago.) The number and types of connectors on the backs of TVs have changed radically over the years, but all those connectors pass signals. 30 years ago, it was not uncommon for two wires to come from an antenna on top of the TV or up on the roof. All the antennae cable passed was the image that appeared on the screen — without any data about time, channel, audio, etc. Now, the typical input is an HDMI cable that carries a ton of data — some slow, some fast, but all signals.

It’s vitally important to communicate what types of signals your cables need to carry at the beginning of your search for a cable assembly manufacturer. For example, Meridian is capable of manufacturing a wide variety of cables that carry signals. However, we are not able to make coax cables that carry signals in the high gigahertz range. Having candid initial conversations with clear requirements can save you a lot of time. The good news is you don’t need to know the exact technical parameters or specifications that will be transmitted for cable. Often, knowing the gadgets to be connected to the cable assembly and any standards the signals must conform to helps the Meridian team determine whether we can make the cable or not. If we can’t, we’ll be happy to let you know companies that can.

Questions to Consider before Talking to a Cable Assembly Manufacturer

If you are tasked with finding a cable assembly vendor, here is a simple checklist of questions to think through before you start reaching out:electric cable assembly manufacturer

  1. Can samples be made with off-the-shelf cable? If yes, then you can go to a lot of different vendors. If not then you need a vendor who can extrude cable, like Meridian.
  2. Does the cable need to carry signal, power or both? If only signal or power that makes it a lot easier to find a vendor. If it needs to carry both then a custom cable extruder like Meridian might be needed.
  3. If power is needed; how much? This can be expressed in technical terms (voltage/current) or by knowing what items need the power. For example, a cell phone, data input tablet, fork truck or nuclear power plant.
  4. If signal is needed; what kind? Many signals have technical names/specification numbers. If those are known the problem is solved and if not knowing the devices passing/receiving the signal will go a long way in determining what is needed.
  5. Lastly, how many assemblies are needed? This can be as low as one up to millions. It can be several for prototype, then more for Beta/First Articles/PPAP, and then on to production quantities. All vendors have a volume sweet spot. Knowing the quantity can often help save valuable time ruling vendors both in and out.

Hopefully this very simple guideline helped. (Apologies to any engineers who read this and found some of it is not technically pure. We’re happy to talk more technically…maybe a little too happy.) Obviously, there are many items to consider when designing and producing a custom cable assembly. This basic approach will help make the process of finding the right cable assembly manufacturer a little easier.

At Meridian, we have experienced designing and extruding a wide range of custom cables. If you’re ready to talk about what we can do for you, please get in touch.

Special Considerations for Military Cable Assemblies

Special Considerations for Military Cable Assemblies

Military cable assemblies must withstand constant use in variable climates and harsh conditions.

In many ways, custom military cable assemblies have the same basic requirements as cable assemblies for other industries: They must carry power or information from one place to another. The difference with military assemblies is that they are often required to perform in much harsher environments, and it is even more critical than commercial products that they do not fail. Because of this, military cable assemblies are subject to exacting standards that are crucial for a wire and harness manufacturer to meet.

Dependable Cables for Military Applications

As previously stated, with military cable assemblies failure is not an option. In many cases, equipment is mobile and meant to be deployed rapidly in combat situations. This means military cable assemblies must be able to withstand extreme temperatures and conditions with heavy shocks, vibration, dust, and moisture. When designing these cables, it’s essential to keep all of these considerations top of mind.


Producing a cable that is designed to the optimal flexural requirements can ensure it is sturdy enough to withstand the frequent stretching, twisting, and contracting of heavy use. Depending on the specific requirements of the machinery, Meridian’s engineer may recommend a coiled cord or stranded cores in the individual wires to enhance the cable’s flexibility.


Beyond the stresses that come with continual use are environmental considerations that range from larger issues like temperature and climate to more immediate concerns like vibration of the equipment. We are able to design military cable assemblies that address the most challenging conditions using a wide range of techniques, such as tooling to create strain reliefs and overmolded connectors that withstand harsh environments.

Customized Applications

Whether securing communications to field units or powering bases overseas, each branch of the military uses cabling and wiring that must be tailored to their specific applications. Sometimes, a cable must be ever more versatile. For example, the complex wiring of an airplane can require cables that must reach from one end of the plane to the other, encountering different areas with different conditions along its path.

Complying with Military Standards

When producing custom military assemblies, it is important to work with a cable and wire manufacturer that understands the importance of following specifications and requirements meticulously. Meridian Cable always strives to maintain the highest quality product while meeting the exacting standards of military specifications. From design through production, our team is committed to adhering exactly to specs and maintaining open communication to address any issues as they arise.

The engineers at Meridian Cable have valuable experience producing customized military cable assemblies that meet requirements for quality and durability. We work with a wide range of materials and are able to provide solutions for a variety of applications. Please contact us if you have any questions or would like to discuss what we can do for you.

Why use a molded cable assembly?

Why use a molded cable assembly?

A molded cable assembly might just be the perfect solution for equipment that is used in harsher environments.

The success of a custom cable assembly often relies on its ability to withstand environmental conditions. Harsh conditions can include areas where there are extreme temperatures, or fluids are present that could damage the conductors. The cable assembly’s termination point may need to be durable enough to withstand vibration or continual flexing without failing. These are among the many issues that can be addressed by working with a cable manufacturer to design a custom molded cable assembly.

Creating Stronger Cables with Overmolding

At its most basic, overmolding is a process for surrounding a component and cable assembly with plastic to protect important parts. It is a great way to address potential wear and tear because it allows us to tailor your cable assembly to both your equipment and the environment. Overmolding can be used for:

  • Strain Relief for Connectors & Enclosure Exit Points – These are points where connectors are attached to cables or even reinforce a section of cable that must pass through a housing or enclosure.
  • Cable Breakouts – Also called “Y” or “J” junctions, these are the point where a conductor or conductors leave the main cable.
  • Cable Stops – An anchor point that the cable assembly passes through.
  • Seals & Glands – Seals and glands are used to provide additional protection to the end  of a cable assembly that attaches to the equipment.  

The Right Material for the Job

When it comes to different applications, the right material can make the difference between an effective cable and one that fails due to a conductor breaking or coming into contact with moisture. There are quite a few materials that can be used depending on the type of problem we are addressing with the overmolding process, including:

  • Polyvinylchloride (PVC)
  • Thermoplastic elastomer (TPE)
  • Thermoplastic vulcanizate (TPV)
  • Polyurethane (PU)
  • Thermoplastic polyester elastomer (TPEE)
  • Silicone

During the design phase, we can determine the hardness or softness of each material to create the most effective molded cable assembly solution for your application.   

Overmolding Process

The process to create a molded cable assembly with an injection molding machine is fairly straightforward. The machine is fitted with a mold that has been selected or created to match your specifications. The appropriate resin is added to the machine, where it is mixed with any colorants. The machine heats the resin and forces it into the mold. As the resin cools, it takes on the properties of the mold, and you have a molded cable assembly that looks and functions the way your want.

Meridian Cable maintains an inventory of more than 5,000 molds, which allows us to design a cable assembly that is not only durable, but matched perfectly to your specifications. In additions to the variety of molds, we are also able to further customize your molded cable assembly conductor sizes and colors, stranding sizes, conductor insulations, fillers, wraps and shields, and jacketing materials. We can also incorporate standard cable types and UL certified wire and cable where appropriate. Get in touch to find out how we can help you make a better cable assembly for your equipment.