What is a Cable Assembly Prototype?

Prototype custom cable assemblies are vital to the testing and production phase when developing a product. Industries can assess, examine, and perform equipment trial runs before mass production. As a critical component of the development process, a prototype cable assembly allows industries to inspect products and save money by assuring confidence in their efficacy and functionality. Prototype assemblies play a valuable role in a wide array of industries, including medicine , military , telecommunications , industrial production , and more. As an instrumental factor in product development, prototype cable assemblies allow companies to validate their design before escalating to full-scale production. Ultimately, prototype assemblies save time and effort in the long run by circumnavigating costly design errors or calculations before the expense of mass production.

How does a cable assembly drawing work?

Our design engineers pay attention to the little things. In cable manufacturing, the little things make all the difference. Attention to the fine detail creates consistent quality cable assemblies. The same principle applies to prototype assemblies. When we work with your team to design a custom prototype assembly, we take the time to cover each detail and explore the minutiae of design. From the day you contact our team, we are set to craft a one-of-a-kind design ideally suited to your connection needs. We develop your prototype from the conductor out, offering unique conductor sizes, stranding, shielding, and other customizations. Our engineers are some of the best in the business and stress tiny details to ensure we get it just right. We conduct extensive research on your equipment to know the ends and outs of what you need in a cable assembly. The result of all this detailed research is a prototype assembly that passes every test we can throw at it. Once we've gathered the information we need to create a design, we'll develop a customized digital rendering of your cable assembly prototype. The digital version allows us to make adjustments, tweak design flaws, and go back to the drawing board when necessary. All this takes place before a physical prototype is ever created. Once you receive your physical prototype, you can rest easy, knowing it's been through the wringer of detailed design work and the unparalleled scrutiny of our quality assurance team.

How do you find an experienced custom cable design engineer?

We've cultivated a team of some of the most experienced design engineers to provide excellence and expertise in every product we create. Our staff brings decades of experience and invaluable insight into the development and manufacturing of custom wiring solutions to the table. When you work with our team, you have complete access to our talented engineers. From sales to manufacturing, our staff is comprised of some of the best in the business and the most outstanding people. Our model of continuous improvement relies on complete customer satisfaction which happens with intentional design, attention to detail, and a dedicated team that’s with you every step of the way.

Will Meridian Cable help my company design a flat ribbon cable assembly?

Certainly! Our team of in-house design engineers will help design and create the ideal custom flat ribbon cable assemblies for your needs. We work with you through every step of the process to ensure your satisfaction and the quality of your cable solution. The design phase of production is a crucial part of creating flat ribbon cable assemblies. During this portion of the process, our team will take the time to understand your unique cable needs and begin designing a custom solution. We draft a digital design of your flat ribbon cable assemblies from the design stage and run preliminary screening tests to ensure it meets your needs. Because of the importance of the design stage, our engineers work directly with you throughout the entire process.

What are the benefits of using flat ribbon cable assemblies?

Flat ribbon cable assemblies have a lot to offer in terms of benefits and capacity. For one, a flat ribbon cable has the ability to mass terminate, meaning it can connect to multiple ports/connections at once. In contrast with a round cable assembly , in which there can only be one termination per port, flat ribbon cable assemblies have multiple terminations in a linear structure. Flat ribbon cables can be built to correspond with any number of different port configurations. This flexibility gives flat cables the ability to be custom designed to suit the specific needs of equipment and function. Their unique design lends itself to a wide range of applications and industrial processes. One of the most common benefits of a flat ribbon cable assembly is that its structure can fit in small spaces like a computer. This allows them to be used in nearly every industry that uses technology.

What is the difference between a cable and a ribbon cable?

Traditional cable assemblies are composed of cables that are generally rounded and have a spiral interior structure. Flat ribbon cables, however, have the conductors structured linearly so that they are side-by-side to form a flat structure. This design allows flat ribbon cables to fold into smaller spaces and have multiple terminations at each end. Practically, flat ribbon cables have a lot to offer in terms of flexibility and adaptability to a plethora of applications. The unique linear design of flat ribbon cables can be configured into the ideal solution for custom equipment. Their design often works better in computers than a standard cable because of the flat ribbon cable’s flexibility.

Why should I choose Meridian Cable to build my cable solutions?

Having been in the cable production business for several decades, we understand that there are numerous cable manufacturers out there. While you certainly could purchase from any old cable production company, you may not be getting the solution your unique situation demands. When you buy an off-the-shelf cable solution, it is going to be a generic cable that may or may not do what you need. We’ve been in this business long enough to know that a one-size-fits-all approach should not apply to cables. We create a custom flat ribbon cable solution from the design up, meaning it is always exactly what’s required to solve the task at hand. We work with our clients to build the ideal solution to the most exacting detail. When you choose Meridian Cable, you get our custom design process, our years of experience, and our top-notch quality cable solutions. You can trust our team with any of your flat ribbon cable needs.

What is the purpose of insulation in flat ribbon cable assemblies?

Insulation serves a very important role in the function of a flat ribbon cable. The conductor on the inside of each cable transfers high amounts of data and electricity in pulses. While these electrical pulses are often low voltage, they need to be contained within the cable to properly function and avoid loose electricity in the area surrounding the cable. The insulation in a flat ribbon cable keeps the electricity flowing through the conductor and allows the cable to transfer data and power correctly and safely. During the design phase, you can choose from different insulators that will best suit the purpose of your cable solution. Getting the appropriate materials for the job is important with an important component like insulation.

What are UL-Certified cables?

UL-Certification is the gold standard within the cable industry. Underwriters’ Laboratories (UL) has developed a multi-level certification standard by which cables are measured for quality and reliability. This rigorous certification means that the cables, components, and manufacturing processes are all of the highest ethical and industrial standards. In other words, a UL-Certified cable is one that has been built and tested to ensure that it meets qualification standards for safety, integrity, functionality, and reliability. Meridian Cable is proud to say that we offer UL-Certified cable assemblies , wire harnesses , flat ribbon cable assemblies, and more . You can trust that when we make your cable solution, it will be crafted and vetted to the highest standards and most precise detail. With a UL certification, you can rest easy knowing that your cable solution is both capable and well-made.

Where are Meridian’s cables manufactured?

Meridian Cable has multiple facilities where we manufacture our cable solutions. Over the course of several decades, we have grown our business to be a world leader in cable manufacturing. Between our first facility in Tanggu, China to our US-based facility in St. Augustine, Florida , we supply the world with custom cable assemblies and more. In 1999, we had to make the difficult decision to close our facility in the United States. However, just a few years later, business was booming, and we were able to bring our manufacturing back to the USA. Now, in our 7,000-square-foot advanced manufacturing facility in Florida, we are able to provide jobs to our community in the areas of St. Augustine. With facilities literally around the world, we are able to deliver the perfect solution no matter where our clients need us.

Is there a warranty for flat ribbon cable assemblies?

When you purchase a custom cable solution, it likely represents a significant investment for your business. Meridian Cable stands behind every product we manufacture. Our in-house engineering team designs every cable to the most precise detail, so it is exactly what you need. Standing behind our work, we offer a complete, one-year warranty on the manufacturing and components. When you choose Meridian Cable for your flat ribbon cable solutions, your investment is well-founded. We manufacture our cables to the highest standards and hold to rigorous, UL-Certified qualifications and several internationally-recognized certifications. If that were not enough, you can always trust in our several decades-worth of experience and our outstanding team of experts. We only hire the best of the best for engineering, manufacturing, and design. We take our business seriously and expect our products to be top-notch.

Can I test my flat ribbon cable assemblies before they are mass-produced?

Certainly. As part of our stringent testing process, we can create a prototype to ensure that the solution works well for your equipment. This will give you a tangible representation of the design and the larger order that is yet to be produced. With every one of the flat ribbon cable assemblies that we manufacture, we perform intense testing, reworking, and configuring. If there is an issue with the prototype, we can go back to the drawing board and redesign a viable solution. We do this to be certain that our cables are the ideal solution and will be precisely what your equipment needs.

How does Meridian Cable assure the quality of its flat ribbon cable assemblies?

Over the past several decades, we have become proficient at designing and producing our cable solutions. With our experience in the industry, we have developed intense testing procedures to guarantee the top-notch quality of our flat ribbon cable assemblies. Each cable we produce will undergo a myriad of stress tests, manufacturing inspections, and practical functionality tests to ensure that it is upheld to UL-Certified standards . Even by the time the prototype is developed, our flat ribbon cable assemblies have been subjected to virtual testing to ensure it will function in simulations. This testing helps us ensure the design of your cable solution has the highest probability for success before we even start the physical manufacturing. We want to do everything we can to provide dependable cable solutions of the highest industry standards.

What industries use flat ribbon cable assemblies?

Because flat ribbon cables are often used in computers, their applications are virtually limitless. In our multiple decades of experience in the cable production industry, we have made flat ribbon cables for a range of businesses. We have created thousands of flat ribbon cables for the medical sector, military, telecommunications, and industrial production. One of the beauties of flat ribbon cable assemblies is that they can be found anywhere in some capacity. Their flexible design makes them a valuable cable option for every industry imaginable.

What is custom wire harness manufacturing?

Custom wire harness assembly entails creating a custom set-up of electrical wires and/or cables based on the task needed by our client. You can imagine this can run a pretty large gambit of different applications. As custom wire harness manufacturers, it is our job to fully understand the client’s needs, examine where the cable harness will be used, and consider a host other factors that determine the material types and attributes needed for the wiring harness to perform under even the harshest of conditions for years of faithful, continued service. At Meridian, we have the tools and experience to create just about any wiring harness application a client can think of. We usually produce a small number of prototypes to ensure our engineers have everything perfect for the unique application our client is intending before we move on to larger-scale production.

What are wiring harnesses used for?

Wiring harnesses are used in everything from remote control cars to jumbo jets. For example, the desktop computer you may be using currently has a myriad of different harnesses for data and power transfer, all to let you view a page like this one. Inside your vehicle are reams of cables, wires, terminals, and connectors that have to run through the entire vehicle in order to connect all the different components that allow you to simply drive from A to B. The harness itself sounds simple, but it can be rather complex when different connections, terminations, conductor sizes, sheathing, strain reliefs, and many other considerations have to come into play depending on the needs of the project. Our engineers design a complete system around the wires and cables needed to power electrical systems, transfer high speed data, and send and receive signals. If you’re ready to discuss your project’s unique requirements, talk over your options with a knowledgeable representative now .

Are there different types of wiring harnesses?

The different types of wiring harnesses is only limited by your imagination. As we continue to increase our reliance on electrical systems powering even simply devices, the engineering inside of these applications requires custom made wiring and cable harnesses to complete the intended application. Each project requires its own custom set-up in order to be designed and manufactured to be able to effectively complete the task required of it. As you can imagine, this will be quite different for a remote control car versus a fighter jet, yet each require exact engineering design in order to function. From military applications, industrial, medical, telecommunications, and almost every industry in between, we design custom wire harness solutions that work.

Are all aftermarket wiring harnesses the same?

Definitely not. Unfortunately, shoddy manufacturers abound and buying a harness from a non-reputable wiring harness supplier can put your project’s assets at serious risk of failure. At Meridian, we follow strict quality assurance/quality control procedures, use and maintain UL® standards for wiring, and are proud to have received and maintain ISO 9001:2015 certification for quality. We do all of this to ensure we remain wire harness and cable assembly manufacturers of distinction, engineering the precise solutions our clients demand, and making sure these systems are robust enough to stand up to years of use.

Where can I find custom wire harness manufacturers near me?

We strive to make sourcing cable assemblies and wiring harnesses easy. That’s why we operate two manufacturing facilities both in the U.S. and in China . We own both facilities, so we stay intimately abreast of the day-to-day operations of each. We are UL®-approved for wire harness manufacturing so you can be confident in the exact requirements of your project being met by our design staff. With two, independent facilities running around the globe, we ensure your project is completed on-time and on-budget, using the best materials and methods available in wire harness manufacturing today. So no matter where your project takes place, be confident knowing Meridian can supply all the components needed to produce a top-of-the-line custom cable harness.

What is the wire harness manufacturing process?

For any custom cable or wire harness project, our engineers and design staff first listen to our clients. By intimately understanding the “what, when, where, and how” behind the harnesses’ intended application, we can begin the manufacturing process. Often, we need to understand the electrical needs, as well as, the space constraints first and foremost and build our systems within the project’s scope concerning these dimensions. Each process is a little different for each custom harness and Meridian craftsmen have more than 5,000 tools at their disposal to get the job done. Depending on the level of precision the project calls for, we can either deploy hand tools, semi-automated machines, or fully automated machines. Even though we depend on automation to provide exact design specifications, a lot of work is still done by hand by our skilled manufacturers due to the multitude of complex steps involved. Our process engineers deploy time and money savings techniques like kanban manufacturing and just-in-time ordering to provide the very best products possible, on-time, and within our client’s budget. After we’ve figured out the ins and outs of the project’s unique manufacturing process, we usually develop a prototype for client approval and verification that it will meet their needs. Once approved, we move to larger scale production and ship our products to clients all over the world.

What is the UL® standard for wire harness manufacturers?

United Laboratories (UL) is one of only a select few corporations that have been approved by the U.S. Occupational Safety and Health Administration (OSHA) for testing and certifying both safety and uniform functionality of wiring and cable components. By only using UL-certified components , we can ensure our products operate the same way, within known specification ranges, year in and year out. Rather than having to design a cable from scratch each time, this allows design staff to focus on other project variables such as weight strain reduction within the harness, type and size of conductors, insulation material, etc. If you don’t see that your wire harness and cable assembly manufacturers are using UL-certified wires and cables, don’t trust your integral electrical systems to a system which could fail when you need it the most.

What is the difference between a cable assembly and a wire assembly?

These often confused components are quite different and serve different purposes. A wire is either a single strand or a bundle of strands that are designed to be conductive. Wires come bare or sheathed and are usually made of copper or aluminum. Conversely, a cable has two or more conductors which are insulated which are then twisted together, usually inside of a protective outer jacket. A wire harness therefore, is the systematic support system that links wires into a cohesive unit with the necessary connections and terminations to complete the task. Think the wiring system in your automobile that requires different systems to all be linked simultaneously. While a cable assembly is similar in concept, the application is quite different and would include examples like the fairly simple cable assembly for connecting your TV and surround sound or the more complex and futuristic-looking electrode helmets used in medical brain scans.

What is ISO 9001:2015 certification?

The International Organization for Standardization (ISO) specifies the minimum requirements that the quality assurance/quality control plans a manufacturer has to have in place in order to be certified for ISO 9001:2015 . For this system governing quality management systems, the organization needs to show that it has the ability to consistently deliver the products or services that meet both customer and regulatory requirements, as well as, show they’ve taken steps to enhance the customer’s satisfaction. This is done through demonstrating the organization has continual improvement processes in place and can showcase conformity to customer/regulatory requirements for each project undertaken. Meridian is proud to maintain this important distinction for ensuring our clients receive nothing but high-quality products.

Does Meridian offer a warranty for wire harnesses?

Meridian designs products under the strictest of quality assurance and quality control guidelines, but components do sometimes break down prematurely. We want you to be absolutely confident in your decision to use Meridian as your wire harness supplier of choice so we stand behind our products with a warranty against material defects or workmanship under normal use and service for a period of one (1) year from the original date of invoice. Depending on the situation, Meridian will either repair or replace the product.

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

Cable assemblies are often confused with wiring harnesses , but these two vital components of almost every electrical system on the face of the planet both play different roles in conducting electricity and transmitting signals. For one, cables and wires are two different things. A wire is a single strand of a conductive material like copper. A cable is a twisted bundle of wires, with insulation, and a protective outer jacket. Wiring harnesses provide the physical support system for combining different wires in cables within a larger system like the electrical system of a car. A cable assembly can run the gamut from simple applications such as a coax cable transmitting signals from a television to a sound system, to incredibly complex bundles of sometimes well over 50 different conductors distributing electricity and signals throughout a system like the cockpit of a fighter jet.

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

As with most choices in life, you have a variety of options to choose from when it comes to cable assembly manufacturers to meet your needs. You can buy off-the-shelf cable assemblies but these are usually quite simple due to their need to be mass-produced for a limited purpose. Most consumers see “custom” and think this equates to more expensive. Actually, our custom designs usually save our clients money in the long run because it helps cut sourcing costs, production time, and reduces chances for defects. Meridian has been in the business of cable assembly manufacturing for nearly three decades. In that time, we’ve gotten pretty good at what we do. We’ve fully integrated kanban manufacturing, which eliminates waste in the production process, saving time and money. We’ve also created custom tool cribs with more than 5,000 specialized tools and equipment so we can adapt the manufacturing process quickly when required. Finally, we maintain several industry-leading certifications like ISO 9001:2015 , IATF16949 and use UL-certified wires and cables during assembly. This means we can create a custom solution that’s been tested and retested for continuity, integrity, and functionality. When you need a cable assembly solution you know you can count on, choose a manufacturer with the track record to deliver your vital components.

What different types of applications are cable assemblies used in?

Cable assemblies are used in just about every electrical system on the planet. At Meridian, we focus on manufacturing quality cable assembly components in four key industries: Industrial Control , Medical , Telecommunications , and Military . However, because our design capabilities are so versatile, we can design the perfect set-up for just about any application you can imagine. Our engineers love solving our client’s complex problems with products that work, year in and year out. One of our greatest strengths lies in producing product start-ups. In fact, over 70% of the products we produce are custom-designed by our brilliant cable and wire design architects.

Why do cable assemblies need fillers?

Fillers inside the cable assembly can be easily overlooked for their supposed simplicity. Even by name, “filler” doesn’t conjure up an indispensable component of the overall assembly. However, fillers do, in fact, provide several critical support functions to the cable assembly. Most designs of a custom cable assembly require using wires with differing diameters. Fillers help maintain the round shape of the cable which produces both a uniform appearance and provides support. Filler tapes also help maintain the shape and prevent tangling. As well, they help expel any trapped air pockets in the wires. Different applications will require advanced levels of strength, flexibility, and durability which fillers like aramid fiber and steel can provide. Fillers also help reduce the amount of friction between the cables which, in turn, extends the life of the cable. Far from being just “filler”, the materials that help fill the gaps in a cable assembly play an integral role in the form, function, and longevity of almost every cable assembly manufactured.

Why does Meridian use UL-Certified cables?

UL-certification means United Laboratories (UL) has independently tested a product to determine if the product meets a standard, specific, and defined requirements. These requirements are usually based on functionality and safety. UL is one of only a handful of corporations that have received authorization from the U.S. Government to provide testing services. By using UL-certified products , Meridian design staff don’t have to start from scratch with design components and know going into a project the differing parameters that a component can withstand inside of a system. This helps ensure products remain consistent in their functionality throughout the product life cycle. When the component is helping power vital systems from industries like the military and medical fields, the function is simply too crucial to leave up to fate so standardized products with known specifications are employed.

Are Meridian’s cable assemblies made in the USA?

Yes, but we also have a production facility in China that’s been in continuous operation for more than 20 years. Both our St. Augustine, Florida and Tanggu, China production facilities are solely owned and operated by Meridian meaning we have full control over even the smallest details of day-to-day operations. We leverage our different facilities logistically to be able to manufacture and ship cable assemblies and other products to customers the world over. Ready to talk over your project specifications with our design team? Call, Click, or Come in Today.

Does Meridian offer a warranty for custom cable assemblies?

At Meridian, we want you to have full confidence in your decision to trust your important cable assembly components to us. While our products are designed with incredible attention to detail and are run through a battery of quality assurance tests to ensure they function as they are intended, sometimes products do fail prematurely. Therefore, we offer a full, one-year warranty against material defects and workmanship.

Can Meridian create a custom prototype for my cable assembly?

Absolutely. Creating product start-ups is an area we’ve become incredibly proficient in. It’s quite rare for any of our products to go from concept to full-scale production without prototypes, rigorous testing, and possibly several redesigns in between. Most of the products we sell are custom-designed solutions. We know your custom cable assembly simply has to perform. That’s why our on-staff cable assembly engineers and design team work hard during prototyping to ensure we’ve designed a system that will work in the unique application you intend it for. We also have 3D printers to create items for review before any tooling is made, which can reduce tooling iterations, and cost.

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

Nearly three decades leading the way for cable assembly suppliers has left us pretty good at what we do. Still, we are always seeking ways to improve our systems and processes to remain on the absolute cutting edge. To maintain our ISO 9001:2015 certification, we have to demonstrate we have the ability to consistently deliver our products that meet both customer and regulatory requirements and also that we have systems in place that aim to continually improve our processes. At Meridian, every single product that rolls of the line is tested each and every time. Sometimes, this requires engineering a brand-new way of testing when the product is something totally new. Our factory even has an entire lab dedicated to testing products, testing advanced applications, and helping to qualify new designs. This fanatical attention to Quality Assurance allows us to deliver consistent products to customers, who know they can count on the cable assembly to perform as designed for years to come. We’re even able to help customers get their products certified through a myriad of certification agencies whenever there is a need.

Why are cable assemblies used by OEMs?

Original Equipment Manufacturers (OEMs) need components that are the same as what was originally input in a system, like an automobile. OEMs will specify the exact requirements for a mass-produced component like a cable assembly for a vehicle and we can help manufacture this to identical predetermined specifications. This helps save time and money during the manufacturing and installation process as the parts will be uniform to the originals.

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