Getting the correct quote for your custom cable assembly project may seem like a hassle at first glance, but when you work with the right people, the sky's the limit. Whether you're designing a new product, updating an existing system, or replacing obsolete components in your facility, understanding the factors that impact your custom cable assembly cost will help you plan your project budget more effectively from the beginning.
At Meridian Cable, we strive for excellence in everything we do, from a simplified ordering process to cutting-edge USA manufacturing processes. We are here to help you every step of the way as you create and receive your custom cables and assemblies. As a leading custom cable manufacturer, you can rely on our expert guidance to determine your precise custom cable assembly cost.
What Impacts Custom Cable Assembly Cost?
Building a custom cable assembly goes beyond simply assembling a few wires and cables—it requires a detailed and multifaceted plan to accomplish. Numerous key elements can influence the cost of custom cables and assemblies. We take into account the most minute details to provide an accurate quote for the tailored solution that fits your needs and budget.
Our team works closely with clients to understand their specific needs and the essential details of each project. We consider factors such as:
- Materials: The type of wire, instulation, shielding, and connectors you select have a direct impact on the cost of your custom cable assembly. Based on your equipment and transmission needs, your project may require a higher-performing material, which can impact your overall price.
- Configuration complexity: Intricate designs with numerous branches, shielding requirements, or specific configurations may affect production costs.
- Conductor size and type: At Meridian, we custom extrude our conductors, allowing us to create the precise conductor size from the appropriate material tailored to your equipment and transmission needs.
- Connectors & Extra Elements: We offer over 5,000 unique options for extra elements and components to complement your custom cable assembly. Depending on your design, you can choose various elements to enhance connectability, convenience, organization, or other factors that may impact your cost.
- Order volume: Naturally, your order volume is a significant factor in calculating the cost of your custom cable assembly.
Information We’ll Need to Provide an Accurate Quote
When requesting a quote from a cable assembly manufacturer, providing more details upfront will result in a more accurate estimate. Of course, we understand if you need help identifying certain factors, but the more information you can provide, the better.
Identifying the specific components and elements of your custom cable design is critical for ensuring a practical solution that strikes all the right notes. Because we're building your custom cable project from scratch, every small detail matters. Our design team will explore the following areas with you during the quote process:
Industry & Application
First things first, we'll need to know details about your industry. Certain sectors demand specific elements and accommodations for their custom cables and assemblies. For example, if you're in the medical industry, we understand that you'll be working with delicate and sensitive equipment, biometric components, and high-intensity environments. These factors will impact the elements your cable assembly requires.
Once we ascertain your industry, we will also need to know the specific application for your custom cable assembly. This will help identify the equipment and transfer necessities of your project. Your type of equipment, housing, capacities, and application will help us understand your exact needs, allowing us to create the ideal solution for you.
Type of Cable
One of the first pieces of information we’ll require is your cable type. Knowing whether you need a flat ribbon cable versus a coiled cable assembly will start your design off on the right foot. Of course, each cable type brings something unique to the table, so we'll need to know that information from the beginning.
You have multiple options to create your ideal connection solution. You can choose from cable types such as:
- Flat ribbon cables
- Coiled cables
- Coaxial cables
- Control cables
- SMA cables
- RF cables
- Molex cables
- Shielded cables
- Electrical cables
- and much more!
We'll help you create a custom cable assembly based on your specific needs and the requirements of your equipment and environment.
Conductor
As the core of your custom cables, the conductor material and size may be some of the most significant factors in your assembly. The inner core of your cables is the lifeblood through which signals and electricity are transmitted between ports. Because it's such a critical component, it's essential that we get this element exactly right for your custom cable assembly.
Elements such as conductor size, stranding, and even conductor color can make a significant difference in your custom cable’s functionality and operational success.
Additionally, you may want to incorporate different conducting metals into your cables. While most conductors consist of copper, we can incorporate other elements, such as gold or alloys, into the core of your cables.
In cable assemblies with multiple conductors, consider adding color variations to your schematic to aid in organization. We offer a variety of colors and patterns to help you keep everything neat and tidy, ensuring foolproof connections.
Insulation & Jacket Materials
The inner and outer protective layers help form a barrier between the electrical conducting components and the outer world. These elements can be selected based on your environmental concerns, electromagnetic interference (EMI) potential, conductivity requirements, and more.
You can choose from a range of insulating materials such as,
- Cotton
- Nylon
- Kevlar
- PVC
- Fleece
The jacket materials may vary based on your specific needs. We can choose from elements such as PVC, rubber, and other flexible coatings to ensure a safe and secure connection.
Shielding
In electronically noisy environments, shielding your custom cables may be necessary to prevent interference, disrupted signals, or corrupted data transmission. Shielding provides protection against harmful electromagnetic interference that could cause damage to your equipment and the entire electrical system. This is typically applicable in technologically heavy industries, such as telecommunications or industrial settings.
Shielding around the conductors and insulation materials helps deflect and ground EMI, rendering it inert and allowing safe transmission to continue.
You have the option to choose from foiled, spiral, or braided shielding, depending on the level of protection your cables require.
Connectors/Terminals
Other crucial elements you may need to know are the ports and terminals to which your wires and cables will connect in your system. Ports can vary significantly across sectors, so it is essential to understand the precise docking points.
Choosing the correct connectors is a critical element of designing a reliable custom cable assembly. The right connector ensures secure electrical connections, enhances mechanical stability, and stabilizes the overall performance of the cable. With your connector, it's important to consider elements such as environment, potential hazards, vibration, temperature, compatibility, current, and safety elements.
Overmolded Components
Overmolding can improve the durability and longevity of your custom cable assembly. This process codes the entire assembly in a secure protective layer that defends the cable and conductor from significant environmental hazards, such as moisture, chemical interaction, vibration, and abrasive interactions. Overmolding also provides strain relief that can prevent mechanical failures, a critical element in industrial and military environments.
Environmental Conditions
The environment plays a significant part in the elements you choose for your custom cables and assemblies. If your equipment lives in hazardous conditions, you may require a more rugged cable assembly to ensure safety and secure operations.
Environmental conditions may include potential vibrations or abrasive situations, extreme moisture or temperatures, dust, or heavy electronic presence. We will consider these factors when drafting the drawing of your custom cable assembly.
Why Choose a Custom Cable Manufacturer?
You may be wondering why you should use a custom cable manufacturer instead of an off-the-shelf solution. The short answer is customization. While you may find a universal cable assembly that does some of what you need, there's no one-size-fits-all solution when it comes to electrical systems.
When you use custom cable assembly manufacturers, like Meridian, you can rest assured that your solution is built to meet your specific and precise needs. Because your custom cable assembly is, well, custom, it's built to your most exacting specifications, accounting for every detail, and ensuring meticulous performance capabilities.
You don't have to force a universal solution into your unique system with a custom cable assembly from Meridian. This makes for a seamless and hassle-free integration process, saving you time and frustration.
Why Choose Custom Cables From Meridian?
We've been in the industry for multiple decades, developing and honing our skills as a leading custom cable manufacturer. As a global standard in the industry, we understand the particulars that go into making a custom cable assembly from design to delivery. Our team of engineers has what it takes to help you create the ideal solution that you can count on day in and day out. While you may find a cable from just about anywhere, you won't find our experience or expertise anywhere else.
Get Started Today!
Do you have an idea for a custom cable assembly project of your own? We can help! We’ll deliver an accurate quote to get started on your project and get you more connected. Get in touch with us today to get started.
