Creating quality, high-functioning custom cable assemblies begins with the smallest of details and ends with highly satisfying results. Meridian Cable has been a leader in the custom cable assembly industry for several decades and creates entirely custom cable assemblies and wire harnesses for every industry imaginable. Our years of experience and innovation has led to our extruding conductors and building cables that are reliable, durable, and high-functioning. 

Since 1994, Meridian Cable has manufactured custom cable assemblies to meet the exact specifications of our customers in a myriad of applications and industries. We create a precise custom cable assembly or wire harness to perfectly meet the demands of our clients’ advanced electronic equipment. 

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Custom Cable Assemblies Manufacturer - It's Who We Are

In order to create a high-capacity custom cable assembly, the first step is to extrude the conductors. The conductors are the metallic components that transfer power or data within the cable. The process of extruding the conductors begins with pulling the metal into long, extremely thin wires and then spiraling the wires around themselves to create the core of a cable.

When creating cables that transfer data in which exactness and accuracy matter most, it is vital to bear in mind the most minute of details. With special attention to the customization options for every custom cable assembly we manufacture, we create cables that are built entirely around the specific application in which you use them. In the end, this means that you get a custom cable assembly to perfectly meet your needs.

5 Things to Ask A Custom Cable Assemblies Manufacturers

Custom Cable Assemblies Services from the Wire Out

When it comes to designing your custom cable assembly, you have a vast array of options to select from. With everything from the conductor size to the jacket materials, your options are entirely yours to select from the inside out.

From the very beginning, we create your custom cable assembly to the exact specifications. With a wide range of customizable options, we offer a completely customizable cable assembly from the ground up. Such customizable options include:

  • Custom conductor sizes
  • Numerous color options for conductors
  • Stranding size options
  • A wide range of insulations materials
  • Options for filler material
  • A plethora of wrapping and shielding options
  • Your choice of jacket materials

With such a wide range of options for custom cable assemblies, you can design a tailor-made cable assembly for every industry and application. No matter what application you need your custom cable assembly for, Meridian Cable will make it be exactly what you need.

Our Custom Cable Assemblies & Engineering Solutions

Meridian Cable has been a leading manufacturer of custom cable assemblies for several decades and stands by every item we make. Every one of our products is rigorously tested to ensure consistent performance, excellence in quality, and longevity in their reliability. Our hands are on the entire process of cable creation, so we hold our handiwork to the highest standards, the most stringent of specifications, and the strictest of expectations.

We extrude our conductors, create our wires, and build our cables every step of the way so that we directly manage each stage of the manufacturing process. This allows us to guarantee their quality and feel confident in their entire makeup, ability, and capabilities.

Because the process of making custom cable assemblies from the ground up is such a labor-intensive process, we at Meridian Cable have found that it is crucial to run rigorous testing and quality assurance on all of the cables we manufacture. We put our cables through the wringer to make certain that they will be reliable and function correctly when you need them to. We have made custom cable assemblies for every industry from the medical field to military applications and we stand behind every single one.

Custom Conductor Size

Depending on the equipment in which you are using your custom cable assembly, you will need to vary the sizes of your conductors. The larger the amount of power your equipment requires, the larger the conductor will need to be. If your conductor is too small for the amount of electricity running through it, it could cause your insulation to burn up, melt, or even ignite. This would certainly damage your cables and would most likely cause harm to your equipment.

Choosing the correctly sized conductor for your equipment is an essential part of the design process for your custom cable assembly. By selecting the right size of the conductor, your cable will be well equipped for your specific application and industry.

The conductors for your custom cable assembly can be created in a wide range of sizes depending on what application and capacity in which the cables will be used. The customizable sizes range from as small as 34 gauge to as large as 12 gauge and can be combined to create a mixed gauge cable with any combination of the sizes in between.

Select your Conductor Color

Because Meridian Cable creates custom cable assemblies for an endless variety of equipment with multiple cables in each assembly, it is important to keep track of which conductor goes to which connection. This is why we can create your custom cable assembly with over 25 colors. In addition to color choice, you can add stripes, dashes, or custom text to be certain of each cable’s intended port.

Through the organization and color-coding of each conductor in your custom cable assembly, you can easily create a system of cables that is both easy to install and simple to replicate. Though this is helpful in every custom cable assembly, keeping organized is vital within industries such as the medical field, military, and industrial controls. Because these industries handle sensitive data, highly volatile equipment, and potentially hazardous materials, it is imperative to keep organized and not get your wires crossed.

Choose the Right Stranding Size

When designing your custom cable assembly, an important step is selecting the proper stranding size. Stranding is the coil of wires that are twisted together in a spiral as opposed to a single and straight wire. The stranding allows multiple wires to transfer power and data more rapidly than a single wire can and more effectively disperses the electricity. Stranded cables can be made from just copper, tinned stranding, tinned conductor, or lined with more rare metals for optimum performance.

Another benefit of a stranded cable is that it offers much more flexibility and scalability that can aid in the adaptability of your custom cable assembly. The different stranding sizes and makeup can make all the difference for your custom cable assembly. We offer multiple stranding sizes to best suit your needs, with a wide range from as small as 0.002” to as large as 0.023”.

Insulation and Fillers

You are well on your way to creating your custom cable assembly from the wire outward. The next crucial component of your cable is the insulation. Insulation plays an essential role in your cable and has a dual purpose to protect the conductors from outer elements, as well as aid in containing the electricity.

The insulation within the cables of your custom cable assembly can be made from a variety of materials like Teflon, natural rubber, PVC, PE, or PP. Depending on what you are using your custom cable assembly for, you will have the option to choose the material used for your insulation.

Selecting the filler for the cables within your custom cable assembly is one of the final steps in the design process. The filler has a distinct purpose of giving the cable a distinct shape and form. Again, depending on the purpose of your custom cable assembly, this filler can be any of the following materials:

  • Cotton
  • Nylon
  • Kevlar
  • PVC
  • Fleece

Add Shielding and Wrapping

Once the insulation and filler have been added, your cable within your custom cable assembly is near completion. At this stage, the cables have the conductors, stranding, conductor colors, insulation, and filler. At this point of the design, most cables require adding shielding or wrapping as an additional layer of protection to the conductors. This can be made from a number of different materials that are designed for varying levels of flexibility, durability, and protection.

Finally, Select the Jacket Material

The final stage of the cable assembly is the addition of the cable jacket. The jacket is the outermost layer of protection for the cables within your custom cable assembly and can be made from a wide variety of materials. Depending on your needs, we can create your cable jackets to maximize flexibility, increase durability, or perhaps add a layer of moisture protection for your conductors.

Request a Quote for Your Own Custom Cable Assemblies

Now that you have built the cable within your custom cable assembly from the wire out, you are ready to start the process of building the entire cable assembly. Meridian Cable can help walk you through the entire process of creating your own custom cable assemblies. Request a quote from Meridian Cable today to talk over the specs for your custom cable assembly.

Custom Cable Assembly FAQs

Meridian Cable Assemblies Manufacturers

When it comes to cable assemblies, your cable assembly manufacturer needs to be intimately familiar with your intended application, taking into account all of the variables that can play into longevity and performance. To do so requires experience, skill, and capability. Meridian’s engineers design products that stand up to the rigors of their environment because our products are used in everything from military and medical, to telecommunications and automobiles. These components are simply too vital to fail prematurely. Read on as we explore some of the more frequently asked questions we’ve received concerning Meridian’s options for cable assemblies. We are a cable assembly manufacturer in the USA.

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