Custom Cable Assemblies

Cable assemblies are often confused with wiring harnesses, but these two vital components of almost every electrical system on the face of the planet both play different roles in conducting electricity and transmitting signals. For one, cables and wires are two different things. A wire is a single strand of a conductive material like copper. A cable is a twisted bundle of wires, with insulation, and a protective outer jacket. Wiring harnesses provide the physical support system for combining different wires in cables within a larger system like the electrical system of a car. A cable assembly can run the gamut from simple applications such as a coax cable transmitting signals from a television to a sound system, to incredibly complex bundles of sometimes well over 50 different conductors distributing electricity and signals throughout a system like the cockpit of a fighter jet.

As with most choices in life, you have a variety of options to choose from when it comes to cable assembly manufacturers to meet your needs. You can buy off-the-shelf cable assemblies but these are usually quite simple due to their need to be mass-produced for a limited purpose. Most consumers see “custom” and think this equates to more expensive. Actually, our custom designs usually save our clients money in the long run because it helps cut sourcing costs, production time, and reduces chances for defects. Meridian has been in the business of cable assembly manufacturing for nearly three decades. In that time, we’ve gotten pretty good at what we do. We’ve fully integrated kanban manufacturing, which eliminates waste in the production process, saving time and money. We’ve also created custom tool cribs with more than 5,000 specialized tools and equipment so we can adapt the manufacturing process quickly when required.

Finally, we maintain several industry-leading certifications like ISO 9001:2015, IATF16949 and use UL-certified wires and cables during assembly. This means we can create a custom solution that’s been tested and retested for continuity, integrity, and functionality. When you need a cable assembly solution you know you can count on, choose a manufacturer with the track record to deliver your vital components.

Cable assemblies are used in just about every electrical system on the planet. At Meridian, we focus on manufacturing quality cable assembly components in four key industries: Industrial Control, Medical, Telecommunications, and Military. However, because our design capabilities are so versatile, we can design the perfect set-up for just about any application you can imagine. Our engineers love solving our client’s complex problems with products that work, year in and year out. One of our greatest strengths lies in producing product start-ups. In fact, over 70% of the products we produce are custom-designed by our brilliant cable and wire design architects.

Fillers inside the cable assembly can be easily overlooked for their supposed simplicity. Even by name, “filler” doesn’t conjure up an indispensable component of the overall assembly. However, fillers do, in fact, provide several critical support functions to the cable assembly. Most designs of a custom cable assembly require using wires with differing diameters. Fillers help maintain the round shape of the cable which produces both a uniform appearance and provides support. Filler tapes also help maintain the shape and prevent tangling. As well, they help expel any trapped air pockets in the wires. Different applications will require advanced levels of strength, flexibility, and durability which fillers like aramid fiber and steel can provide. Fillers also help reduce the amount of friction between the cables which, in turn, extends the life of the cable. Far from being just “filler”, the materials that help fill the gaps in a cable assembly play an integral role in the form, function, and longevity of almost every cable assembly manufactured.

UL-certification means United Laboratories (UL) has independently tested a product to determine if the product meets a standard, specific, and defined requirements. These requirements are usually based on functionality and safety. UL is one of only a handful of corporations that have received authorization from the U.S. Government to provide testing services. By using UL-certified products, Meridian design staff don’t have to start from scratch with design components and know going into a project the differing parameters that a component can withstand inside of a system. This helps ensure products remain consistent in their functionality throughout the product life cycle. When the component is helping power vital systems from industries like the military and medical fields, the function is simply too crucial to leave up to fate so standardized products with known specifications are employed.

Yes, but we also have a production facility in China that’s been in continuous operation for more than 20 years. Both our St. Augustine, Florida and Tanggu, China production facilities are solely owned and operated by Meridian meaning we have full control over even the smallest details of day-to-day operations. We leverage our different facilities logistically to be able to manufacture and ship cable assemblies and other products to customers the world over. Ready to talk over your project specifications with our design team? Call, Click, or Come in Today.

At Meridian, we want you to have full confidence in your decision to trust your important cable assembly components to us. While our products are designed with incredible attention to detail and are run through a battery of quality assurance tests to ensure they function as they are intended, sometimes products do fail prematurely. Therefore, we offer a full, one-year warrantyagainst material defects and workmanship.

Absolutely. Creating product start-ups is an area we’ve become incredibly proficient in. It’s quite rare for any of our products to go from concept to full-scale production without prototypes, rigorous testing, and possibly several redesigns in between. Most of the products we sell are custom-designed solutions. We know your custom cable assembly simply has to perform. That’s why our on-staff cable assembly engineers and design team work hard during prototyping to ensure we’ve designed a system that will work in the unique application you intend it for. We also have 3D printers to create items for review before any tooling is made, which can reduce tooling iterations, and cost.

Nearly three decades leading the way for cable assembly suppliers has left us pretty good at what we do. Still, we are always seeking ways to improve our systems and processes to remain on the absolute cutting edge. To maintain our ISO 9001:2015 certification, we have to demonstrate we have the ability to consistently deliver our products that meet both customer and regulatory requirements and also that we have systems in place that aim to continually improve our processes. At Meridian, every single product that rolls of the line is tested each and every time. Sometimes, this requires engineering a brand-new way of testing when the product is something totally new. Our factory even has an entire lab dedicated to testing products, testing advanced applications, and helping to qualify new designs. This fanatical attention to Quality Assurance allows us to deliver consistent products to customers, who know they can count on the cable assembly to perform as designed for years to come. We’re even able to help customers get their products certified through a myriad of certification agencies whenever there is a need.

Original Equipment Manufacturers (OEMs) need components that are the same as what was originally input in a system, like an automobile. OEMs will specify the exact requirements for a mass-produced component like a cable assembly for a vehicle and we can help manufacture this to identical predetermined specifications. This helps save time and money during the manufacturing and installation process as the parts will be uniform to the originals.