Cable assembly with 5, RG174 coax cables

EEG Electrodes

Twin mono plug connector

Right angle, sealing grommet

Custom Cable Assembly Manufacturer

 

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. 

Building Custom Cable Assemblies Begins With the Little Things5 Things to Ask A Custom Cable Assemblies Manufacturers

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. 

Creating Custom Cable Assemblies to Be Proud Of

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. 

Completely Customizable Cable Assemblies 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. 

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. 

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.

What’s the difference between a cable assembly and a wiring harness?

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.

How do I choose a cable assembly manufacturer from the many cable assembly companies out there?

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.

What different types of applications are cable assemblies used in?

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.

Why do cable assemblies need fillers?

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.

Why does Meridian use UL-Certified cables?

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.

Are Meridian’s cable assemblies made in the USA?

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.

Does Meridian offer a warranty for custom cable assemblies?

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 warranty against material defects and workmanship.

Can Meridian create a custom prototype for my cable assembly?

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.

What kind of Quality Assurance process does Meridian use for cable assemblies?

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.

Why are cable assemblies used by OEMs?

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.

Get a

QUOTE

from Meridian

  • Coax, Twisted Pair, DC Power, Coil Cord, Custom
  • Allowed file extensions: .pdf, .doc, .docx, .xls, .zip
    Drop files here or
    Accepted file types: pdf, doc, docx, xls, zip, Max. file size: 256 MB, Max. files: 5.
    • This field is for validation purposes and should be left unchanged.