Cable assembly with 5, RG174 coax cables

EEG Electrodes

Twin mono plug connector

Right angle, sealing grommet

Cable Assembly Manufacturer

A cable assembly is only as good as its parts, and this starts with the cable itself. At Meridian Cable, we extrude our conductors and our cable to the most exacting specifications. We offer custom cable assembly design expertise and have manufactured cable assemblies to fit a vast spectrum of flexural requirements. These abilities allow Meridian Cable to create the custom cable assembly solutions needed in a wide range of industries.

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Customizable Features

Conductor Sizes

We can extrude conductors as small as 34 gauge and as large as 12 gauge. These can be combined to create a mixed gauge cable.

  • 34 awg
  • 32 awg
  • 30 awg
  • 28 awg
  • 26 awg
  • 24 awg
  • 22 awg
  • 20 awg
  • 18 awg
  • 16 awg
  • 14 awg
  • 12 awg

Conductor Colors

As one of the leading cable assembly manufacturers, we make cable with many conductors sometimes well over 50. To keep track of the conductors, we can use different colors. We can also mark the electric cables in other ways with stripes, dashes or even text to ensure the right conductor goes to the right spot.

AVAILABLE COLORS

  • black
  • white
  • red
  • green
  • brown
  • blue
  • orange
  • yellow
  • purple
  • gray
  • pink
  • tan
  • white/black
  • red/black
  • green/black
  • orange/black
  • blue/black
  • red/white
  • green/white
  • blue/white
  • orange/red

Stranding Sizes

Your conductors can be made with stranding as small as 0.002 inches (0.05mm) which is excellent for hi-flex, supple cables. If you just need a standard power conductor, we can use stranding as large as 0.01 inches (0.25 mm). Stranding can be bare copper, tinned stranding, tinned conductor or even plated with precious metals such as silver for increased conductivity.

SIZES

  • 0.002″
  • 0.003″
  • 0.004″
  • 0.005″
  • 0.006″
  • 0.007″
  • 0.008″
  • 0.009″
  • 0.010″
  • 0.013″
  • 0.016″
  • 0.020″
  • 0.023″

Conductor Insulation

The first protection in any cable is the conductor’s insulation. We use the range from basic PVC, PE or PP. We also use insulating materials for electric cable assemblies such as natural rubber, PU, TPE, PTFE (Teflon) and silicone.

MATERIALS

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

The hardness or softness of each material can be varied.

Fillers

To make a cable perform its best, it is often necessary to include fillers inside electric the cable. We use materials from basic cotton to nylon to Kevlar. Each material is custom matched to the applications requirement to ensure proper performance.

  • Cotton
  • Nylon
  • Kevlar
  • PVC
  • Fleece

Wraps and Shields

Often a cable’s conductors need to be wrapped or shielded. High flex cables require a soft barrier between the conductors and outer jacket to prevent abrasion. Many electronic cables need shielding to prevent RFI or EMI interference. We use materials such as fleece, cotton and aluminized mylar, amongst others, to create a cable that will match the operating environment.

Aluminized mylar, Cotton, Fleece, Spiral wrapped stranding, Braided stranding, Polyester tie. This is typically wrapped with spiral overwrap.

Jacket Materials

The final barrier between the environment and the inside of your electric cable is usually its jacket. This final covering acts as an insulator, a shield and protective cover. For your cable we can use materials as simple as PVC or as robust as natural rubber, Teflon or Silicone.

MATERIALS

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

The hardness or softness of each material can be varied.

Cable Types

There are many standard cable types. The cable standards help designers choose a cable with known specifications instead of creating one from scratch. These standards can also be used as building blocks for more complicated designs.

CABLES

  • TPT
  • SP-1
  • SPT-1
  • SP-2
  • SPT-2
  • SP-3
  • SPT-3
  • TS
  • TST
  • SV
  • SVE
  • SVEO
  • SVO
  • SVT
  • SVTO
  • SJ
  • SJE
  • SJEO
  • SJEOW
  • SJO
  • SJOOW
  • SJT
  • SJTO
  • S
  • SE
  • SEO
  • SO
  • SOOW
  • ST
  • STO
  • STOOW
  • HPN
  • HSJ
  • HSJO
  • HS HSO

These can be made in many different gauge configurations.

UL Certified Wire & Cable

There are many standard UL cable types. UL standards help designers choose a cable with known specifications instead of creating one from scratch. We are certified by UL to produce many standard types of wire and cable.

WIRE

  • 1007
  • 1032
  • 1095
  • 1533
  • 1571
  • 1015
  • 1061
  • 1185
  • 1569

CABLE

  • 2029
  • 2464
  • 2562
  • 2725
  • 2833
  • 2919
  • 2992
  • 2096
  • 2468
  • 2661
  • 2733
  • 2835
  • 2990
  • 20080
  • 2405
  • 2560
  • 2689
  • 2789
  • 2991
  • 20276

These can be modified for color and stripping and still be UL certified.

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.

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 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.

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  • Coax, Twisted Pair, DC Power, Coil Cord, Custom
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