Category Archives: Cable Manufacturer

Discussing Filler Materials with Your Cable Assembly Manufacturer

Discussing Filler Materials with Your Cable Assembly Manufacturer

Your choice of filler materials can affect the sequence of components, the strength, and even the appearance of your custom cable.

When meeting with a cable assembly manufacturer, filler materials might not be at the top of your list of subject to discuss. However, filler material is an important component of your finished custom cable and should receive serious consideration. While filler material can certainly be used to fill gaps and create a better appearance, there are other practical uses like enhancing the strength of the cable and/or reducing friction.

Appearance Counts with a Cable Assembly Manufacturerfiller material used by cable assembly manufacturer

In many cases, designing a custom cable assembly requires engineers to use multiple wires with different diameters. While it is possible to leave spaces between the larger wires to accommodate smaller wires, it is still sometimes necessary to use fillers to maintain the round shape of the cable. Maintaining the shape produces a more professional appearance while providing support for outer layers of the cable. Depending on the requirements of the finished cable, these filler materials can be foams, tapes, or even spare wires that are not carrying current.

Filler tapes are often used to bundle wires to maintain shape, but they also prevent tangling and are specifically good for expelling air pockets that are trapped between the wires. They can even be used to group specific wires inside the cable, which can help in processing and ultimately make it easier to attach components.

Filler Materials for Stronger Custom Cables

The appropriate filler material is one of several components that must be taken into consideration when a client requires more strength in their custom cable. Depending on the level of strength needed, there are a wide range of filler materials that can be used — including aramid fiber and steel.

Aramid fiber is a type of synthetic fiber that is strong, flexible, and resists abrasion. It can be used in a wide variety of applications, including clothing and lightweight protective armor (Kevlar™ is a commonly known commercial brand). Aramid fiber also offers additional heat resistance, which may be appropriate for some applications.

Reduce Friction with the Right Filler

Over time, friction can degrade cables. The good news is that there are several steps a custom cable manufacturer can take to reduce friction and extend the life of the cable. One of those steps is to choose the appropriate binder material.

PTFE tape is a great choice for custom cables when friction and heat are concerns. PTFE (or polytetrafluoroethelene) is resistant to heat and friction, and is also a good insulator due to excellent dielectric properties. You may have heard of PTFE referred to under the brand-name Teflon™.

Conclusion

While not every cable requires them, a cable assembly manufacturer can use filler materials to add strength, support, and friction resistance to custom cables. Their use allows the cable to function as effectively as possible while helping to protect it from environmental conditions. Work closely with your cable assembly manufacturer so they are able to select filler materials that fulfill the technical requirements of your equipment while fitting your budget. When you’re ready to talk about your next custom cable, contact the team at Meridian Cable. We look forward to discussing your project.

Talking Jacketing Material with Your Cable Assembly Manufacturer

Talking Jacketing Material with Your Cable Assembly Manufacturer

Choosing the right jacketing material is key to creating a tougher custom cable assembly.

Jacketing material is one of the many features of a custom cable that you should talk about with your cable assembly manufacturer. As the first line of defense against a variety of conditions — including heat, moisture, and chemicals — your choice of jacketing material can make the difference between a durable custom cable and one that fails long before it should. Ensure your finished cable is exactly what you need by covering three main points with your cable assembly manufacturer.

Physical Requirements to Discuss with a Cable Assembly Manufacturer

What is your cable connecting? Do the parts need to move around or are they generally stationary? Does the cable need to stretch? Does it need to resist tears and abrasions? These are just a few of the questions that may come up when discussing a cable’s physical requirements with your cable assembly manufacturer. Once they have the answers, they can weigh the positive and negative characteristics of different jacketing materials to select one that is most appropriate for your cable’s specifications. For example, a polyurethane jacketing has good elastic memory which makes it a solid choice for coil cords and cables that require more flexibility. However, it’s not a good choice if the cable needs to be processed easily.

Environmental Conditions

Beyond the basic physical requirements, a cable also needs to be able to function under a certain set of environmental conditions. These environmental requirements can include resistance to heat, flame, chemicals, and water or even stability over a range of temperatures. There are enough jacketing options available that really fine tuning your cable to the specific conditions of your installation environment is possible in most cases. We can even add a jacketing made of polyvinyl chloride (PVC) that can be made resistant to UV rays or almost as flexibile as a thermoplastic polyestomer.

Cable Appearance

While the look of a cable may not change its electrical or mechanical performance, the appearance is often more than simple cosmetics. Even something as simple as jacketing in a specific color can enhance the safety of the finished product because it helps better differentiate the finished product from other cables. A jacketing can also be designed to match the equipment manufacturer’s overall design aesthetic, which can help users keep the right cable with the right equipment.cable assembly manufacturer jacketing

Finishes can be matte or glossy, depending on your needs. In some cases, a matte finish can make the cable easier to grip, which can be useful for installation and handling in certain conditions. For medical equipment, there are also requirements for cables that may come into contact with skin that include cleaning, disinfection, and sterilization that may dictate the properties of the jacketing.

Conclusion

Jacketing material is one of the many features a cable assembly manufacturer is able to customize to meet your specific needs. With all the options available, it’s important to have an in-depth discussion with an experienced design team to make sure they have all the information they need to select the right materials for your cable. Contact Meridian Cable when you’re ready to get started on a custom cable. Our team looks forward to answering your questions.

5 Points to Discuss with a Custom Cable Manufacturer

5 Points to Discuss with a Custom Cable Manufacturer

Being clear about what you need at the start of your project is key to a successful relationship with your custom cable manufacturer.

Regular readers know we stress good communication with your custom cable manufacturer throughout the design and manufacturing process. More information, especially during the design phase, can help the team address potential issues before they become costly problems further down the road. However, we know it can be difficult to understand what kind of information is the most helpful. So we put together a list of some areas to discuss that will help your next custom cable project go more smoothly and result in a more successful product.

1. Previous Designs

If you are starting from scratch with a design for a brand new cable, you can probably skip this conversation. But if you’re replacing an existing cable assembly, this is the perfect opportunity to improve on the previous design. Talk to your custom cable manufacturer about the quality, cost, and performance of your existing cable. Let them know what is and is not working, and what could work better. Using your existing cable as a starting place allows you to really focus on what you need in a cable moving forward.

2. Basic Technical Requirements

This seems obvious, but coming up with a list of requirements for your custom cable manufacturer is a good way to make sure all of the absolute must-haves are met. Requirements might include voltage, number of contacts, signal speed, grounding, etc. Taking some time to understand what you need before the design phase will help save time and money when creating a custom cable assembly.

3. Environmental Concernscustom wire

Not taking the environmental conditions a cable must withstand into consideration during the design phase can be the reason the final product is unsatisfactory or fails prematurely. Concerns like moisture, heat, and cold are obvious, but they are not the only types of things you should be thinking about. For example, cables used in medical facilities often have additional requirements to ensure they are able to be sterilized for use with multiple patients. But, this is only one of many situations that you should talk through with your custom cable manufacturer.

4. Connector Types

A custom cable manufacturer can use a wide variety of connectors in your cable design, but the two main types are assembled and overmolded. In general, assembled connectors are less expensive to produce and molded connectors tend to be more durable. However, each type has it’s pros and cons, which should be discussed with your cable manufacturer’s engineering team to make sure you make the right choice for your application.

5. Safety Requirements

Most custom cables must comply with safety regulations. A reputable custom cable manufacturer should be able to discuss how their processes ensure the resulting product meets the appropriate standards. However, it’s also important to discuss any special requirements before the design stage to make sure all standards will be met.

Conclusion

Help your custom cable manufacturer design a better cable with some careful thought about what you need. Communicating as many details as you can as early as possible makes the design process run more smoothly and helps make sure your custom cable is tailored to the needs of your equipment. Good communication in the early stages of a project can also help save both time and money both in the short and long terms.

If you’re ready to share the specifications for your next project, contact the team at Meridian Cable. We’re happy to answer any questions!

How to Work with a Cable Assembly Manufacturer When You Have a Tight Budget

How to Work with a Cable Assembly Manufacturer When You Have a Tight Budget

A cable assembly manufacturer has many options available that can help you stay in budget and get a custom cable that is right for your situation.

Having an unlimited budget to work with when designing a custom cord might seem like the best way to get the perfect end product, but that type of situation is rare. In most cases, budget is a concern. The good news is your cable assembly manufacturer should be able to help you balance the cable’s functionality with cost.

Good Communication Saves Money

This may seem like common sense, but make sure you are sharing as much information with your cable assembly manufacturer as possible in the planning and design stages of your project. Having clear specifications about how and in what environment the finished product will function gives the design team a thorough understanding at the outset. This can translate to a cable assembly that meets the needs of the equipment and environment with fewer revisions or surprises late in the project.

Talk Materials with Your Cable Assembly Manufacturer

Armed with complete technical specifications and a good understanding of the environment where a finished cable assembly will function, the design team is able to select the optimum materials to create a solution that operates as expected. At its most basic, a cable is made up of a conductor, connectors, jacketing, and insulation. Each can offer an opportunity for cost savings with some careful thought.

Conductorscable assembly manufacturer conductors

Obviously, the conductor material should be selected based on the type of signal and how long the cable is expected to be in use. However, with so many options when it comes to size, material, and plating, a cable assembly manufacturer can make recommendations that address cost concerns without compromising on functionality. For example: In many cases, a smaller conductor is less expensive. Choosing the smallest conductor that will transmit the signal or power allows you to get the functionality you need without the unnecessary expense of a larger conductor. Though, in some cases, a smaller conductor is actually more expensive to produce, so it’s doubly important to discuss options with your cable’s design team.

Connectors

All cable assemblies connect to some sort of equipment or power/signal source. Because the section of cable that leads to the connector is a common point of failure due to stresses, it’s important to select the right type of connector for the job. While an overmolded cable offers more durability in many cases, it may make more sense to use a connector that can be repaired by a technician. Understanding the needs of your finished product allows you and your cable assembly manufacturer to make the right decision before producing a cable that doesn’t fit your needs.

Jacketing & Insulation

The environment where a cable assembly will be used often dictates what type of jacketing material or insulation is used in the finished product. Different materials are more suitable for cables that are exposed to extreme heat or cold, moisture, or stresses. More expensive materials for jacketing aren’t automatically better for every environment. In many cases, choosing a more costly material that is unsuited for the environment can be a waste of money and compromise the function or service like of the cable.

Conclusion

Good planning, open communication, and thoughtful selection of materials is the great way to save costs when creating a custom cable with a cable assembly manufacturer. If you are ready to talk about your next custom cable project, contact the team at Meridian Cable. We’d love to discuss your options.

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!

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

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.

Signal

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.

Determining the Shape of a Custom Coil Cord

Determining the Shape of a Custom Coil Cord

The shape of a custom coil cord is one of the most important elements when designing this type of cable.

Custom coil cord is known for its flexibility, making it the perfect choice for applications that require a cable that can stretch and retract without putting additional stress on the wire. It has the ability to extend beyond the natural length at rest, which can be a real space-saving feature. These cords are flexible beyond simple extending and retracting in that they can also be pulled, bent, and twisted without experiencing the metal fatigue of a straight cable.

Coiled cable can be used to carry electrical currents as well as data and signal for telecommunications applications. This versatility makes coil cords ideal for use in environments that are often too rough for non-coiled cable. Coil cords are used in everything from equipment on industrial and construction sites to portable electronics, like sound equipment. With so many applications at so many different sizes, the shape of your custom coil cord is key to its successful performance.

Requirements Determine the Shape of Coiled Cable

If you’ve ever seen a telephone cord, you’ll recognize the shape of a coiled cable – curled in the middle with a section of straight cable at each end. While the specifications of the straight sections are important to the overall function of the cable, it is the coiled section that provides the cord with its unique benefits. The retracted length of the cord is how long it is at rest. This is the most common way to specify how long the cord should be. However, it is also necessary to communicate the full length the cord must extend to, so the engineers at your custom cable manufacturer are able to get a full understanding of the requirements of your cable.

The coil’s diameter is a key measurement when determining how far a custom coil cable should extend. In general, a coil with a larger outer diameter with stretch farther than a coil with a smaller outer diameter. When discussing your cable’s specifications with your cable manufacturer, retracted length, extended length, and outer coil diameter will provide a good starting place for the designer regarding the cable’s physical shape.

Fine-Tuning a Cable’s Performance

While you may be able to get pretty close to the final shape of your custom coil cable on your own, the cable’s construction and materials are best selected with the help of an experienced wire and cable manufacturer. Selecting specific fillers and jacketing materials can also add durability to the finished cord. Depending on how tough you need your cable to be, materials can include:custom coil cord

  • PU
  • PTEE
  • TPR
  • SVO
  • SJOW
  • Kevlar®
  • Spectra®
  • Teflon®

An expert cable manufacturer like Meridian Cable, learns everything they can about how your coil cable needs to function. This allows them to make the best recommendations on the materials and physical shape to ensure the finished cable meets the needs of your product or equipment. Rest assured that no matter what your application, a custom coil cord solution can be designed and produced to perfectly match your specifications.

Design Services from Custom Wire and Cable Manufacturers

Design Services from Custom Wire and Cable Manufacturers

New products or pieces of machinery often have unique, specific requirements that can’t be met by stock cable

When developing a new product, the last thing you should be worrying about is whether there’s an existing cable that meets all the requirements for performance, durability, and price. The reality is that there may not be an existing solution that will meet all your requirements at a reasonable price point. And while your engineers may know what your cable needs to do, they most likely lack the experience with different conductors, jacketing materials, fillers, and insulations required to design a cable from scratch. Custom wire and cable manufacturers can provide a level of expertise in the area of electrical engineering that can save time and cost while developing the right cable for your application.

Designing a custom cable can be a challenging process, but a reputable cable and wire manufacturer acts as a partner every step of the way. They will walk you through the process to ensure that they are using the appropriate materials for your precise requirements. In many cases, they can even produce a prototype that allows you to test the cable on your product.

Thorough Consultations Make for Great Designs

The best way to ensure your custom cable meets all of your product’s requirements is to share as much information with your wire and cable manufacturer as possible. The first step in this process is to meet with their engineering team to share all of the specifications, as well as any applicable drawings. Don’t forget to make sure your drawings are created in a common format that can be easily accessed by the manufacturer. This will save both time and frustration for both parties.

As the next step, the manufacturer’s electrical engineering team will review your product’s specifications to ensure they have the capabilities to produce the type of cable you need on your requested timeline. It may be that they do not have the equipment or facilities to produce your cable. At this point, their team should be able to give you an idea of why they are not able to meet your specifications, whether the job requirements are realistic, and possibly make recommendations on how to feasibly produce the cable.

Collaborating with Wire and Cable Manufacturers on a Successful Cable Solution

Wire and cable manufacturers are the experts on customized cabling solutions, but you are the expert on your product. They will continue to hold conversations with you throughout the design process regarding voltage ratings, electrical tolerance, environmental parameters, and flexibility to ensure they choose a conductor material that performs as expected.

Further conversations about the cable’s function and expected environmental conditions will inform recommendations about insulating and jacketing materials. They may ask questions like:

  • Does the cable need to withstand high temperatures?
  • Does it require extra protection, like metal armoring?
  • Are there concerns about signal interference?
  • Does it need to meet spec standards like, UL, CSA, CE, or Mil-Spec?

Keeping Communication Open

Open communication is the key to ensuring positive relationships with wire and cable manufacturers. Designing a custom cable can be a complicated process, but if you provide their team with as much information as possible, it doesn’t have to be frustrating. And don’t forget to speak up if you need help. Experienced engineers, like the team at Meridian Cable, are always happy to answer your questions.

Cable Assembly Manufacturer

Partner with a Cable Assembly Manufacturer to increase your product’s efficiency and functionality with specialized colors, connectors, and more.

Cable Assembly Manufacturer
Cable Assembly Manufacturer

Customizing Your Product with the Help of a Cable Assembly Manufacturer

As any manufacturer can attest to, the more components a product has, the higher the risk of installation errors, added complexity for customers, and increased production times. A product with a complex wiring system is not exempt from this and can have detrimental, and potentially dangerous results if the wiring is not properly installed.

Cable Assembly Manufacturer
Cable Assembly Manufacturer

To make the manufacturing process as streamlined as possible, while remaining mindful of production times, it is often necessary to work with a cable assembly manufacturer to produce assemblies and wire harnesses that will meet your product’s specific needs. Working with a manufacturer and their team of designers and engineers opens up an array of options and specifications that can be applied to your product including:
Selecting the color of your custom wiring and cable
Developing an intuitive wiring diagram to reduce manufacturing errors
Increasing assembly speeds and creating a product that is easier for consumers to install

The Benefits of Color-Coded Custom Wiring

Custom-made wiring and cable can be designed to match almost any existing product or desired look. This is helpful for stylized products or when masking cords and cables so that they are less visible. Manufacturing techniques have evolved so that these products can be made in almost any color and can be produced in a variety of finishes to match your final product.

Aside from altering a product’s appearance, customizing the color of your wire can also serve as an important safety feature. Color-coding cables and wires can greatly reduce the chances of a wiring element being incorrectly installed. Visibly labeling the wires this way can streamline the installation process to make production faster, easier, and more accurate.

Speeding Up Production Cycles And Manufacturing

Production times can be decreased by giving those installing these wiring systems just one wire harness or cable assembly to work with. This reduces the need to track down other products and individual wires. When possible, combining multiple wires to form one cable is also beneficial and can reduce the number of connections that must be made during the manufacturing process.

Reducing Production Errors

The risk of production errors can be decreased by using wire harnesses and cable assemblies. These products are beneficial because they ensure that the proper wires are being used and that none are duplicated or left out. This not only streamlines installation but also makes troubleshooting a faster process as all of the wiring components are neatly housed together.

Improving Your Customer Experience With A Cabling Assembly

Cable assemblies can benefit products that require customer assembly. Opening a new product and finding a tangled heap of cords and wires is overwhelming for consumers and can urge many to make a call to customer service or struggle to ensure that they are wiring their new product properly.

This frustration can be eliminated by using a well-labeled wire harness. Handling just one wiring system instead of several small wires is easier and reduces much of the headache that results from having to untangle a heap of cords. This will help customers to discern the product’s layout and where the specific connectors belong, in some cases reducing the number of individual connections by consolidating several wires into one cord. Simplifying the installation process leads to happy customers and has the ability to reduce customer service call volumes.

Working with a manufacturer to create specific, user-friendly wiring systems is a great way to simplify your product’s manufacturing and installation process. By reducing the chances of errors during installation, your product’s safety and reliability can be improved drastically. This manufacturing method also has the potential to speed up production by making cords easier to identify, sort, and store.

Creating Efficient and Functional Products With the Help of a Cable Assembly Manufacturer

Markings on Custom Cables

Understanding the colors and markings on your custom cabling.

The basics of custom design cables’ markings and symbols, and what the Markings on Custom Cables mean for your product.

Custom design cables may have a series of markings on them that are intended to denote their function and proper usage. As a cable customer, you want to ensure that your cabling complies with industry standards and norms to avoid confusion while making installation and maintenance as simple as possible for the end user. Here are some of the common Markings on Custom Cables along with indicators that often appear on quality customized cable.

The Lettering and Markings on Custom Cables

Markings on Custom Cables
Markings on Custom Cables

When designing cable, the manufacturer will often print lettering on the product’s jacketing during production. The purpose of this lettering is to let users know about the product’s specifications before installing it. Below are some of the letters that are commonly used in custom cable design and what they mean.

  • H – This indicates that the wire is safe to use in temperatures that will not exceed 75°C.
  • HH–  This combination means that the cables or wiring were designed to withstand temperatures that will not exceed 90°C.
  • T – The letter “T” indicates that the custom cables have thermoplastic jacketing. This type of jacketing is made of a durable material that has the ability to insulate and protect your wiring – even in rugged or industrial uses.
  • X– The “X” typically indicates that the wire’s jacketing is made of a thermoset material. Thermosets have a higher heat tolerance than thermoplastics, which typically makes them more suitable for higher temperature applications.
  • W – “W” typically indicates that the product is safe for use in conditions that may be damp or involve contact with water.
  • N – This wire has a nylon coating, the benefit of nylon is that it can protect your product from abrasions and from several corrosive materials such as oil and gas.

The Color of Your Custom Cable

Many of these combinations will depend on the geographic location of the final product and the standards there. To avoid confusion, it is important to ask your manufacturer to research this before making a final decision.

It is also important to note that the different color combinations used in wiring projects vary based on a number of additional factors including the type of project, the number of conductors associated with it, and the aesthetic of the final project. Because of these factors, you will likely need to rely on your wire manufacturer and designer to determine the most appropriate color combinations for your product’s cable or wire.

At Meridian, we have the capability to design custom cable in a variety of colors and color combinations to match the aesthetic of your product, speed up installation, and promote safe maintenance. We also have the ability to manufacture these products, producing prototypes along the way to ensure your product’s efficiency and functionality.

Decoding The Markings on Your Custom Design Cables