Category Archives: Custom Cables

Custom Cable Manufacturers: Creating Endless Possibilities With Your Custom Cable Design

Based on the combinations of each level of design of a custom cable assembly, there seems to be an endless number of possibilities for creating a unique, never-seen-before amalgamation of cables, wires, and support materials. These innocuous materials come together by fanatical design to pull-off some of the most demanding jobs on the planet. From supporting our military men and women on tough missions, providing for the possibility of cutting-edge medical equipment to be employed by a skilled surgeon in a complicated surgery, or enabling the manufacture of millions of other products in an industrial setting, it all starts with humble cables and wires. We’ll explore how the different design layers come together to create a masterpiece of modern engineering that is the custom cable assembly.

Conductor Size Matters

Extruding conductors sounds like the name of a cool sci-fi flick but it’s actually the foundation of any cable assembly. Conductors are simply materials that are good at conducting; think copper, aluminum, or nickel. Extrusion is a series of processes where parts of cable assemblies’ cross sections are made. The conductor material of choice is fed into a large vertical hopper that in turn feeds the extruder machine. The extruder looks like a large screw with a barrel that’s heated so it can mix, melt, and pump the material into a die. Meridian’s brilliant design staff can extrude conductors as small as 34 gauge – about six one-thousandths of an inch, or as large as 12 gauge. Even cooler, oftentimes different gauge conductors are put together to accomplish different tasks within an electrical system. This type of cable is referred to as the mixed-gauge cable. Custom cable manufacturers mix and match gauges to meet the exact requirements, as well as, confines of the project.

Colors of the Rainbow

Color may seem a purely aesthetic choice but far from trying to keep up with the latest season’s fashion, colors help designers and installers keep track of the many different conductors within the cable assembly. At Meridian, we often make cable assemblies with well over 50 different conductors. Just to keep track, we have to use a color system. Colors and custom markings help ensure the right conductor goes exactly where it’s designed to within the cable assembly. The best cable manufacturers reverse engineer cable assemblies from their given applications so that installers can efficiently utilize the assembly in their unique circumstances. Color coding is one way to ensure the product works as intended from design through implementation. 

Leave No Strand Behind

Stranding is the process by which individual conductor strands are joined together. Using a really cool stranding machine, we take strands of wire and rotate them around a common axis to create a super strong and flexible cross-section. When using UL-certified wires, we know the industry specifications of each individual wire and produce a custom cable that performs under the given set of circumstances we plan for. The strands themselves can be an incredible array of different materials and sizes, depending on the level of connectivity an electrical system requires. Cable manufacturing companies typically leave no strand behind unless a single, large strand is the best conductor for the given objective.

Why Insulate a Cable Assembly?

Insulation provides the first line of defense for a cable. Insulators are non-conductive materials that act as separations for the conductors within the cable and also from the environment that could downgrade the effectiveness of the cable if exposed to the elements. Electrical and signal transmission cables will both use insulation to protect conductors from things like extreme temperature variants, friction, current/signal degradation, and moisture. Insulators themselves come in many different types of materials that then each have their own set of design specifications, like hardness and softness, that can be tweaked on a given project. Meridian offers a wide array of insulation materials to meet both budget and performance requirements of each project. Each insulator we employ in a custom assembly will have the specific properties needed to perform under the circumstances. Mechanical properties like operating temperature ranges, resistance to abrasion, and flexibility, electrical properties like dielectric loss (ability to dissipate electromagnetic energy), and physical properties like thermal expansion and resistance to moisture all need to be considered in the cable assembly’s design. Meridian’s design engineers are intimately familiar with each of our insulating materials’ inherent properties so they can hand-pick the perfect combination that meets the project’s unique requirements.

Fillers Can be a Good Thing

Like insulation, fillers are used to prevent abrasion between cables which can degrade their construction over time. Basic cotton and fleece are great low-cost options for fillers that provide protection for the cables, help maintain the cable’s shape, and strengthen the cable through thousands of flexings. For applications requiring more beefy specifications, Kevlar is a great insulator for its inherent strength and durability – not to mention its sweet ability to stop bullets in other applications. Custom wire and cable manufacturers utilize even simple materials like fillers to create the perfect set-up for the intended application of a cable assembly. Far from being just a “filler” within the assembly, cable assembly fillers play a critical role in both form and function.

Cable Armor: Wraps and Shields

Adding to the layers of protection and durability, cable wraps and shields are used to create a cushioned, pliable barrier between the conductors and the final outer jacket. This helps prevent friction, increases strength, and adds to the overall durability of the cable assembly. Also, many electronic cables need special shielding to prevent interferences like electromagnetic interference (EMI) and radio-frequency interference (RFI). This happens when an external source, both man-made and natural, directly affects the electrical circuit, which can degrade the current or cause it to cease altogether. Engineering in an avoidance system to EMI and RFI, our design team is able to create a cable system that can operate unimpeded through many useful cycles. EMI can be an intentional act such as the case with radar-jamming in military applications. Specialized shielding like aluminized mylar helps to block EMI, which allows our soldiers to openly communicate with each other on the battlefield.

Last Line of Defense: The Cable Jacket

The cable jacket acts as a final insulator and a protective barrier from the elements. The jacket can be made in myriad materials ranging from hard to soft to give our clients the protection of their custom cable assembly project needs. Simple materials like polyvinyl chloride (PVC) ranging to Polytetrafluoroethylene (Teflon), recognized for its use in non-stick, high-end cooking, can be utilized to create the perfect jacket to insulate all of the components from the elements in which they’ll be deployed. Nature throws a lot at cable assemblies like heat, oxidation, and moisture that would rapidly deteriorate the conductors and insulation materials without a robust jacket encasing the assembly.

Bringing it all Together

Each step in the production process requires an incredible level of detail to tweak the material to the exact specifications of the project. Our design engineers love being brought an unsolvable problem and putting together a solution that works for both budget and performance. These materials by themselves are just a bunch of seemingly commonplace components, but together, they can be formed into the cable assembly system to power a fighter jet or an electrical system for a Grand Prix race car. We combine the right materials for the right application to produce a one-of-a-kind solution that works. Simply put, we are passionate about exceeding our clients’ expectations and our passion is continuously showcased in our products.

Meridian Knows Custom Cable Assemblies

We know you have many choices in the cable manufacturing industry. Custom wire and cable manufacturers around the world boast of superior products and services. So why Meridian? First and foremost, we have almost three decades of experience in international manufacturing in order to bring our customers around the globe the perfect product, by the most judicious means possible. Our design staff has created cable assemblies for some of the most demanding applications the Earth has to offer. From military to medical, we take the trust placed in our products seriously so produce the very best we possibly can. We also have garnered incredible knowledge in pre-project planning so create an incredibly lean manufacturing process – saving our client’s time and money and producing an ROI time and again. Lastly, we place a huge emphasis on quality. We only use UL-certified cables and wires and even created our own testing lab to ensure each and every product that rolls off our assembly lines perform under the exact specifications to which it was designed. Our products are simply too vital to electrical and signal components to fail prematurely. Our continuing and unwavering commitment to quality is what’s earned us ISO 9001:2015 certification. 
When you’re ready to meet with an engineering team that loves solving even your most complex cable assembly design problems, give our knowledgeable sales and marketing team a call. They’ll help start the process of getting you the perfect custom cable assembly that meets your exact specifications.

Conductor Gauges for Custom Design Cables

Conductor Gauges for Custom Design Cables

The right gauge conductors are key to making your custom design cables as effective as possible.

It’s no secret that creating custom design cables is the best way to ensure your product or equipment meets all of your specifications. Because the conductor gauge directly affects the flow of electricity or signal through the final product, the choice you make is extremely important. Choosing the wrong gauge can result in a less efficient cable that might lead to unnecessary costs. A reputable custom cable manufacturer will help you make the right choice and get the most successful outcome.

Cable Conductor Types

There are two main types of wire: solid and stranded. Solid conductors are a single, solid strand, usually made of copper. Stranded conductors are made up of smaller strands of copper that are twisted together to create a larger conductor. The main difference is that a stranded conductor is better able to withstand bending than a solid conductor. Additionally, solid conductors are less expensive to produce than stranded.

Why Size Counts with Custom Design Cables

custom design cable

For both types, the overall size of the conductor affects the flow of signal and electricity. Signal or electricity flows through larger gauge conductors more easily than it does smaller gauges. We refer to how easily the signal flows through the conductor as resistance. A wire with a conductor gauge that is too small is not providing the right amount of signal to the equipment it is powering. This could result in the equipment not functioning as it should. A too-small conductor gauge could also cause the wire to overheat, which may cause it to fail.

So…Larger Gauges Are Better?

While working with a larger conductor gauge seems like the safest bet, it’s not always the best option for your project. Larger gauges are able to accommodate more current, but they can be more expensive than all but the smallest gauges. In the end, the best gauge for your project is the one that closely matches your equipment specifications. Having an in-depth discussion with your cable manufacturer’s design team about the needs of your product is the most effective way to make sure you end up with a custom cable that functions as expected.

Gauge & Wire Length

When determining the gauge of conductors for custom design cables, the circumference isn’t the only consideration. The final length of the wire also affects the amount of resistance the current experiences. The longer the wire the more resistance there is, which weakens the signal. For longer cables, it may be necessary to use a larger gauge to counteract the resistance caused by the length.

Conclusion

Choosing the right gauge can be a complex process that includes a thorough understanding of the final cable’s uses, length, voltage, and signal type, as well as many other considerations. Working with a cable manufacturer you trust can make all the difference to the success of the final product. The Meridian Cable team has extensive experience with a wide range of custom cable design projects. When you are ready to discuss your next custom cable, please contact us. We look forward to talking with you.      


Cost Effective Custom Design Cables

Cost Effective Custom Design Cables

Generally speaking most people don’t associate custom with cost effective, but they don’t have to be mutually exclusive.

Most of the time, if anything is custom it costs more than a standard counterpart. However, in many cases, knowing what to ask your cable manufacturer will help you keep costs in line. It’s no different with custom design cables or custom cable assemblies.

What are custom design cables and cable assemblies?

Let’s start with the basics and define what a custom design cable or cable assembly is by defining what it isn’t. If you can find the cable or cable assembly you need in stock, it’s not custom. Companies typically don’t stock custom items because they aren’t purchased often enough to justify the cost of carrying the inventory. So, if you’ve searched and can’t find the cable or cable assembly you need off-the-shelf, odds are you need a custom product.

In the immortal words of Douglas Adams, “Don’t panic!” Just because you need something custom doesn’t mean you need to be robbed. Most times the only difference between a standard product and custom product are a few minor, but important, details. Making those changes doesn’t always have to be expensive.

Getting Started on Custom Design Cables

When you can’t find what you need, start looking for a custom product by describing it using standard terms. For example, we make USB cables for the retail security industry that prevent thieves from cutting the cable and running off with a new cell phone. These cables aren’t that different from a standard product except for one very important feature: If someone tries to cut them, they can’t—at least not very easily. While this feature increases the price, it is NOT by factors of 2, 3, or 4. Since we extrude cable, it’s easy for us to include cut resistance in the design phase. This would only add cost for the added material, and not a penny more because we feel like it.

More Complex Custom Design Cables

If the cable you need is a bit more complex, you can describe it as a combination of standards to get your needs across. We recently created a coil cord for an off-the-road vehicle company.  The cable was custom, but it was clearly described as a combination of RS-232, USB, and 12Vdc power. All three are very standard but generally not found in one cable, not to mention in the form of a coil cord. However, when defined by the standard items, it was quite easy to understand what the client needed. custom design cables

Don’t worry if you don’t know the “standards,” like RS232, USB, OBDII, SAE1850, ISO914 L, CAN Bus, UL8750, and so on. You don’t need to be a standards expert; a good custom cable manufacturer will know that stuff and can guide you. Just describe the items you want to connect, or better yet, describe the kinds of cables you want to combine. Then you can ask what standards the manufacturer will design and build the cable to, so you can decide if you really need that standard. Often the only difference between a cable that meets a “standard” and one just like it that doesn’t is nothing but a testing house approving the cable. If you don’t need this seal of approval, don’t pay for it. If you do need it, then it’s a good idea to spend the extra money. Either way, make sure you know so you can make an informed decision.

How much cable do you need?

Last, don’t be fooled into thinking a custom design cable automatically means producing tens of thousands of feet at a time. A good custom cable company should be able to extrude runs of custom cable of no more than a few thousand feet if necessary. Cable extrusion is a fast process, often running at speeds of 3-5 feet per second. It’s not easy to do small runs, but it is not impossible. Many companies just don’t want to do small runs because they aren’t set up for them.  Find a company that is and your costs will be much lower.

Conclusion

Custom cable design doesn’t automatically mean you have to break the bank to pay for the solution you need. Get in touch with the team at Meridian Cable when you are ready to see how we can help you stay in budget on your next custom cable project.

 

 

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.

Designing and Maintaining Your Product’s Customized Wiring

Designing and Maintaining Your Product’s Customized Wiring

Collaborating with a custom cable manufacturer to produce durable wiring that meets your product’s specifications.

Like the majority of industrial products, wiring systems must also be designed and maintained properly in order to withstand harsh conditions. If these products are not looked after and properly attended to, the results can be negative–resulting in a large piece of machinery breaking down and causing delays, or something as catastrophic as a fire. To avoid many of the issues that can result from damaged wiring, it is important to gain an understanding of the customization that your product’s wiring requires and of any maintenance that may be needed. The best place to get this information will likely be from your product’s wire and cable manufacturer. When discussing this, there are a few key elements to keep in mind:

Protecting Your Custom Wiring From Corrosion

The majority of wiring is made of copper, which is susceptible to corrosion when used in harsh or damp conditions. Cables that will be buried, for example, must be coated in a thick jacketing that can withstand conditions underground. Aside from this jacketing, this type of wire must also be sealed so that the soil and any materials in it cannot damage the inner conductor.

Water can also corrode copper over time and most of us have seen the green and white residue that often forms on copper pipes. The wiring’s proximity to water should be considered and addressed by your wiring manufacturer. Specialized techniques can be applied in these instances, particularly if the wiring will come into contact with salt water. When possible, wiring that encounters such conditions should be inspected regularly for signs of damage to the jacketing and residue building up around connectors. Damaged wiring, or wiring that shows signs of corrosion, must be repaired to ensure that it continues to function optimally.

The Right Jacketing Material For Your Custom Wiring

color wire
Designing and Maintaining Your Product’s Customized Wiring

The proper jacketing can be the difference between a long-lasting wiring system and a system that falters. With the proper jacketing, a wiring system should be able to withstand and protect the wiring’s vital conductors from damage resulting from motion, environmental factors including animals and insects, and water if necessary. There are so many additional factors that can alter a wiring system’s functionality that it is important to work with an experienced wire manufacturer who understands your industry and product.

Armed with an understanding of your product and its functionality, your cabling manufacturer should be able to choose an appropriate material that will reduce the wear and tear on your product, minimizing the amount of maintenance that it will require. Contrary to what many assume, there are many types of wire jacketing available to protect your product’s wiring system. This jacketing can be made so that it is resistant to cuts and UV rays, crafted so that it is resistant to high temperatures, and more. The innovation in this industry means that you are sure to find a product that is ideal for your custom wiring needs.

Because of the crucial role that wiring plays in modern machinery and communication, it is important that the wiring you choose to utilize is reliable. To ensure that you are receiving high quality wiring that will last, talk to your manufacturer about the options that are available and the level of specialization that your product or industry demands.

 

Creating Custom Design Cables

Creating Your Own Custom Design Cables

Creating Custom Design Cables
Creating Custom Design Cables

Manufacturing custom design cable on a small-scale.

Working with a cable manufacturer to produce custom design cables for prototypes.

When working on a small-scale project or making a prototype, it’s tempting to try your hand at electrical engineering. After all, you have likely contacted a few wiring and cabling manufacturers and found that they only produce large quantities of wiring. This adds an additional layer of difficulty for those Creating Custom Design Cables on a small-scale; however, finding a manufacturer that produces small quantities of custom design cables can prove to be beneficial. The expertise that a custom manufacturer has to offer can eliminate the additional time, and costs, that often arise when choosing to produce your own custom wiring. Some of the unexpected costs and stressors associated with choosing to craft wire harnesses and cable assemblies without consulting a manufacturer include:

Finding Specialized Tools When Creating Custom Design Cables:

While wiring and cabling often seems straightforward, the process usually requires more tooling than expected. Manufacturer assemblies go through various rounds of testing and quality assurance to ensure that the practices and processes utilized will yield a quality product. Cable manufacturing companies utilize a variety of testing materials beyond multimeters to test their products including clamp testing, life cycle testing, capacitor testing, and more.

Aside from this, specialized training and custom tooling are required to create highly customized wiring systems. One example of this can be seen when working with a wire’s connectors. Some of these connectors need to be soldered to the wire, while others require the use of crimp connectors. Crimping tools can be used for this, but the less expensive hand-held ones are known to be fallible – particularly when the user is inexperienced. Incorrectly crimping a connector can lead to loose connections that create air pockets, deformed connectors that are more likely to break or come apart, and a plethora of other issues.

Finding the Appropriate Materials When Creating Custom Design Cables:

Assembly cabling typically requires a level of specialization that is difficult to find when choosing from off-the-shelf options. The jacketing and filler materials used in the custom wire harnesses and cable assemblies created by trained manufacturers can be made to exacting specifications. These specifications can include resistance to certain types of chemicals and oils, adding protection against UV rays, ensuring that the product is heat rated, and a variety of other useful features.

Understanding the Exact Specifications of Your Wiring:

Calculating the wire gauge that your product requires to function optimally is a difficult process that requires an understanding of industry best practices and standards. These vary based on the type of product that you will be producing, the product’s intended industry, the area that the product will be sold in and more. By working with a manufacturer and their team of engineers, you can ensure that your product meets required safety standards early on in the manufacturing process so that major changes will not have to be made down the line.

Working With Wiring Diagrams on Your Creating Custom Design Cables:

Producing a wiring diagram and planning out the way that the wires and cables will run in your product is an important aspect of the design process. This maps out how long the wires or cables will need to be, where the wires and cables will run to avoid interference, and is an important tool for communicating with other manufacturers about the product’s design and layout. Unfortunately though, many often skip this step when crafting their own wiring or cabling systems. This is detrimental as it becomes increasingly difficult to communicate the layout of the wiring, label the products in use, and ensure that the wires do not interfere with one another. An experienced manufacturer will be able to produce an accurate wiring diagram for your product to eliminate this confusion.

At Meridian Cable, our team specializes in creating small batches of customized products. With our experience creating products on a small-scale, we are able to work with our customers to design wiring and cabling that compliments their products and helps them to run as efficiently as possible. If you need a custom cable, cable assembly, or wire harness – don’t hesitate to contact the Meridian Team.

Creating Custom Design Cables – When it’s Time to Work with a 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
Have Peace of Mind Knowing That You’ve Chosen a Quality Coil Cord Design

Choosing a Quality Coil Cord Design

Choosing a custom cable can be difficult, but understanding the design and manufacturing process can ease that burden, giving your team peace of mind knowing that they’ve produced a quality product with a Quality Coil Cord Design.

 Because a coiled cord’s quality can’t be determined visually, it can be tremendously difficult to determine which designers are capable of producing the highest quality product.

An experienced cable designer will be able to create a cord centered around your product’s specific needs and industry specifications. They will be able to walk you through the design process as their team of engineers gains an understanding of the product’s specific functionality and final application.

Peace of Mind Knowing That You've Chosen a Quality Coil Cord Design
Peace of Mind Knowing That You’ve Chosen a Quality Coil Cord Design

Taking the time to understand the product’s unique cabling needs is important as it ensures that your product will be made with quality materials. When crafting a coiled cord, the jacketing material needs to be durable, yet flexible enough to withstand the constant tugging and stretching that coil cords endure. The conductor inside of the cord must be able to carry the appropriate voltage and signal without experiencing voltage drop or signal corruption. If you’re having trouble assessing whether or not the proposed custom coil will be right for your product, consider some of the following jacketing options and ask your coil cord’s designer about them:

  • Urethane: This coating tends to be a bit more expensive than other options, but it is designed to last and withstand harsh conditions. If your product will be exposed to weathering, this jacketing option may be ideal for you.
  • Cross-linked Polyolefin: This is a highly flexible and cost-efficient option for coil cables, making it ideal for large scale projects.
  • Low Smoke or Halogen Free options: If your wiring will be exposed to high temperatures, you’ll likely need to utilize this type of jacketing as it does not produce harmful chemicals when heated.
  • PVC – For low-cost applications there are formulations of PVC that will work, however, care must be taken to avoid coil cords that stretch out.

Quality Coil Cord Design

Aside from the jacketing that will coat your cable, there are other important considerations that must be taken into account. When designing coil cords for industrial use, it’s also important to consider things like the size of the final product (not just its length, but the size of the cord’s coils as well), the product’s carrying capacity, and the final product’s functionality. Some additional features to keep in mind include:

  • Coil Cord End Direction: This is important because mechanically the straight section should be oriented so that undue strain is not created in the cable. For the wiring to work as effectively as possible, the manufacturer must determine which exit angle will be most effective based on the product and its needs.
  • Stranded Wiring or Tinsel: Stranded wire is more flexible than a solid wire and has a higher resistance to metal fatigue. Tinsel wiring, on the other hand, is ideal for creating flexible wires that don’t require a high current carrying capacity.
  • Outer diameter size: The larger the diameter of your cable, the more likely it is that your cable can carry high voltages and a wider array of signals. If your coil cord must fit within another product, it is important that you and the design team understand the specific size restrictions and create prototypes to ensure that everything works as planned.

With designed cords, it’s important that the manufacturer listens to your concerns and takes the time to learn about your wire’s specific requirements and needs. At Meridian, our customers are our top priority. We strive to meet their needs and work with them throughout the design and production process to create an efficient product.

Meridian Cable’s Quality and Durability Trumps That of Other Cable Assemblies Manufacturers.

A Cable Manufacturer Should Build For Quality and Durability

When creating wiring for logistics purposes, it’s paramount that the cable’s wiring is durable and made to last rugged conditions. Meridian Cable was able to produce this type of cabling for one of their clients, ensuring that it was capable of withstanding rough conditions.

Meridian Cable was recently contacted by a leading logistics company looking for Quality Cable Assemblies Manufacturers to create customized cable assemblies capable of working with a variety of commercial vehicles. This need arose after the U.S. Department of Transportation’s Federal Motor Carrier Safety Administration announced that data logging devices would soon be required in many commercial vehicles. This was done in an effort to create safer highways by effectively tracking how long drivers were on the roadways. Requiring a cable manufacturer who builds products with quality and durability.

Cable Manufacturer Quality and Durability
Cable Manufacturer Quality and Durability

The logistics company that contacted Meridian had no problems manufacturing the data loggers, but struggled to create custom cable assemblies that would work with the wide variety of vehicles that their customers utilized. The issue that they had creating this wiring was two-fold. The first problem was that these data loggers had to fit within a number of different vehicles that varied in year, make, and model. The second issue was that these assemblies needed to be strong enough to withstand rugged environments. The wires used had to be able to function optimally despite bumps and being jostled over the course of long hauls.

Quality and Durability

At Meridian, we specialize in creating customized products for our clients and welcomed the challenge that came with designing these custom assemblies. We understood that the first step would be devising a way to ensure that the type of assembly used with these data loggers would be compatible with a wide array of trucks. Our solution to this was to design a series of customized overmolds. This type of custom cable enabled the data boxes to be linked to a variety of vehicles’ telemetric systems quickly and effectively.

The second issue was rather easy for us to solve. We value quality and put all of the products that we manufacture through a series of tests including advanced life testing labs and various quality control measures. This guarantees that the products we manufacture are of an extremely high quality and are able to function reliably while on the road. This is always crucial, but having this level of security gave the manufacturer peace of mind knowing that their product had the right materials to continue to reliably transmit data, keeping their customers compliant.

Quality Cable Assemblies Manufacturers

Finding Quality Cable Assemblies Manufacturers with this level of versatility required a great deal of design know-how and experience in cable manufacturing. Creating quality assembly cabling is one of the areas that we thrive in, we understand the challenges associated with producing this type of cabling. We strive to gain an understanding of our clients’ products to ensure that we have all of the details needed to produce assembly cabling that exceeds expectations and works seamlessly with their products.

If you’re looking for a manufacturer with experience in the design, production, assembly, and service of wire harnesses – look no further than Meridian Cable to meet your custom cabling needs.