Category Archive: Resources

Our New Portfolios Showcase Our Custom Wire and Cable Capabilities

Through nearly a century of business, Consolidated Electronic Wire & Cable has served a multitude of industries and applications, which has provided us with the experience necessary to fully understand our customers and their electronic wire and cable needs.

This understanding has significantly contributed to the design and construction of our custom cable solutions and has allowed us to manufacture the best product for each of our customers’ unique needs.

Simply put: At Consolidated, we understand your industry, the challenges you face and the solutions you need. 

We encourage you to visit our Portfolios section to view some of the great work we’ve done across a diverse range of industries and applications. Listed below are a few new portfolios, showcasing why Consolidated is a leading manufacturer and national source for electronic wire and cable solutions.

conwire-10.13.15-022-425x319.jpgCustom Hospital-Grade Retractile Cord

The customer’s previous retractile cord hung down and obstructed medical devices, thereby limiting equipment functionality. Consolidated successfully designed a hospital-grade solution that met the client’s exact needs.

Click here to read the full portfolio.

IndustrialControllerPortfolio-retouched-425x305.jpgCustom Cable Harness Assembly for Industrial Controller Panel

Consolidated developed a custom cable harness assembly with a design that would harness a male and female cable to an industrial controller panel.

Click here to read the full portfolio.

conwire-10.13.152.jpgRetractile Cord with Custom Grommet

A customer in the medical field asked Consolidated to develop a custom retractile cord with a 9 Pin D Sub Connector that also met all medical-grade standards.

Click here to read the full portfolio.

Creating a Custom Cable eBookIf you would like additional information on our capabilities and services, visit our Resources section, which contains a variety of downloadable materials related to our company and products.

If you have any questions or would like to discuss how we can assist you with your next project, please contact us today. We look forward to working with you.

American Wire Gauge and Your Next Project

Evaluating the needs of a particular project and familiarizing yourself with gauging systems and the qualities of particular gauges can help to ensure the right wire selection.

American Wire Gauge (AWG) is the official United States standard method for measuring round, solid conductors. The measure, or gauge, denotes the cross-sectional areas of a wire and thus helps to determine its capacity for carrying current as well as resistivity. 
size of cable needed

Gauges are based on whole numbers, of which there are 44 standard AWG sizes, along with size 00, 000 and 0000. Gauging is named by the number of dies a standard wire size passes through during production, and every six gauge increase is the equivalent to a doubling of the wire’s diameter. Every three gauge increase is roughly a doubling of the wire’s area.

Higher gauge, or thinner wire, is broadly optimal for long distances and maintaining conductivity. It’s also more common to find solid wire in a higher gauge.

A wire with a lower gauge number refers to thicker wire. It can carry more amps at a time, but depending upon the application it may not be as effective. The thicker a wire, the more likely it will be most effective as a stranded product.

Wires larger than 0000 or 4/0 are typically measured in 1,000 circular mils (kcmil or MCM), where one cmil is the area of a circle with a diameter of one mil (1/1,000 inch). Also applicable to smaller wires and easily found with a simple formula, the circular mil area of a solid wire is always the equivalent of that wire’s diameter in mils, squared.

Stranded Wire and Gauge

Because of air pockets and varying types of insulation in stranded wire, gauges aren’t quite as straightforward, especially to the naked eye. For any given size in AWG, the stranded wire will take up more physical space than a solid wire equivalent, because the wire gauge is measured based upon the sums of each strand’s cross-sectional area (circular mils), not its overall size

Stranding also affects diameter measurements of the overall wire for the same reasons. The same gauge size in both a solid and stranded conductor can have a very different diameter, as gauge is always a measure of the size of the wire, independent of its insulation or arrangement.

Even stranded conductors with the same gauge size can display different diameters, depending upon the conductor strand types. Different strand types and quantities can produce thousands of combinations to create the ideal conductor for an application, an especially useful quality for wires in larger projects.

AWG and Resistance

The variations in AWG specifically affect a wire’s resistance, which also varies based on material for any conductor (copper, aluminum, silver, etc.). Resistance is essentially the way current will be converted to heat while moving through the wire conductor. Low resistance wire loses less energy to heat.

The larger a conductor, the lower its provided resistance. A stranded conductor tends to have larger electrical resistance than its solid counterpart.

Depending upon a wire’s application, resistance and gauge can be more or less essential. For example:

  • Power Plant Systems: Minimal resistance is essential for efficient transfer.
  • Speaker Circuits: Excessive resistance causes loss of high-frequency energy—the system will sound very different depending upon a proper gauge.
  • Audio Interconnects: These high-impedance circuits aren’t directly affected in a meaningful way by wire gauge.
  • Analog and Digital Video: Wire gauge only moderately influences signal output.

Other Gauging Systems

Not unlike the different measurement systems for volume and distance that we encounter daily, multiple gauging systems have emerged for wire over time.

For instance, the Washburn and Moen (W&M), U.S. Steel, and Music Wire Gauges govern different methods and applications specifically for steel-based wire. You may also find wire measured in Standard Wire Gauge, or SWG. This system is the official Imperial measurement, and it’s sanctioned by the British Board of Trade.

Another British system, the British Standard for metallic materials (BS 6722: 1986), is often used in replacement of SWG. It is based completely on the metric system, and includes wire among other materials. The naming in this system is based upon ten times whatever a wire’s diameter measures in millimeters. You’ll find that these wires are generally labeled and referred to directly by millimeter measurement, skipping the gauge entirely.

Happy Manufacturing Day 2015!

October 2 marks the fourth annual celebration of Manufacturing Day. This year, nearly 1,000 manufacturers across the United States, Puerto Rico, Canada, and Mexico will celebrate the event by opening their doors to the public for open houses, demonstrations, expositions, conferences, and other events.

Manufacturing Day, often shortened to MFD DAY, was founded in 2012 by the Fabricators & Manufacturers Association, International (FMA), the National Association of Manufacturers (NAM), the Manufacturing Extension Partnership (MEP), and the Manufacturing Institute.

These four organizations — among the largest and most important trade organizations in the country — joined together to find a way to help improve the public perception of manufacturing in America.

By bringing manufacturers together with the public, MFG DAY serves several important purposes.

First, it literally brings manufacturers together. MFG DAY has given American manufacturers from across the country and across innumerable industries a way to unify their voices. They can identify common challenges and work together to develop solutions.

Second, MFG DAY allows manufacturers, and manufacturing as a whole, to help dictate their public image. Many Americans have an antiquated view of industry, and MFG DAY allows manufacturers to invite the public to learn what it’s really like.

Third, manufacturers can use MFG DAY to address one of the most serious problems they all face — the shortage of skilled labor. MFG DAY is a vital opportunity for manufacturers to show the public that a career in manufacturing can be very rewarding.

And finally, MFG DAY gives manufacturers the chance to help their communities thrive, for this generation and for all future generations.

Consolidated Electronic Wire & Cable hopes Manufacturing Day 2015 is a huge success for all participants and that our future generations find themselves inspired by the manufacturing industry.

Explore Consolidated’s Informative Technical Resources

At Consolidated Electronic Wire & Cable, we are committed to providing our customers with the resources they need to make an informed decision. On our website, we offer a variety of technical documents with information regarding NEMA configurations, color coding and insulation tips, and other wire and cable specific information.

  • Solid & Stranded AWG Chart: AWG-specification information for all outside diameter & wire types, including solid, concentric, rope bunched & more.PrintedCableJacketPortfolio-retouched
  • NEMA Configurations for Plugs & Receptacles: NEMA plug & receptacle configurations for voltage ranging from 125V to 600V, 15 to 60 amperes.
  • Color Coding Charts: Consolidated Electronic Wire & Cable’s color coding charts for various types of cable & wire products.
  • Wire Insulation Characteristics: A comparison of various types of wire insulation materials, including PVC, polyethylene, polypropylene, rubber, Neoprene, TPR & PEP.
  • NEMA Number Nomenclature: View the NEMA number nomenclature for plugs & receptacles, as well as current ratings & voltages.
  • Cable Standards Reference Guide: View the Cable Standards Reference Guide for NEC catalog reference information and a cable substitution chart.

We encourage you to visit the Technical Info area of our website to view these documents. We hope they prove to be of some use to you and that you find the information you are looking for.

View Our Technical Info Documents

Working with Consolidated Electronic Wire & Cable

No matter the industry or application, customers today face a tremendous number of available choices of manufacturers. Every product and service presents an almost limitless amount of options, as well as the vendors who offer these goods.

homethumb-electrical-wireThe sheer variety can overwhelm procurement managers, OEMs, and other customers. These companies need to be able to easily see what sets a manufacturer apart, why their products and services are beneficial, and why they are a company with whom a customer should partner.

Selecting a Wire & Cable Manufacturer for Your Product

Companies throughout industries rely on wire and cable for a diverse range of projects like electrical service, computer networking, signalization, and security. Each of these applications imposes demands on a manufacturer to be accommodating and dependable, and provide cost-effective wire and cable solutions.

Choosing the right manufacturer and supplier who can offer you an ideal combination of reliability, quality, and affordability requires awareness of a number of factors.

Choosing-A-WireCable-Manufacturer-thumbConsolidated Electronic Wire & Cable’s eBook, Choosing a Wire & Cable Manufacturer for Your Product, offers some important considerations for choosing a reliable wire and cable manufacturer. These include:

  • Capabilities – Begin by examining a manufacturer’s capabilities. If they create a diverse range of wire and cable products, allowing for customization of a number of unique applications, that company is more likely to provide a reliable product.
  • Cost – A reliable wire and cable manufacturer will be able to offer competitive prices, especially on custom and bulk orders.
  • Quality – Make sure that a manufacturer has the proper certifications, like ISO 9001 and QS-9000, which denote attention to detail and quality control throughout the company.

Choosing Consolidated Electronic Wire & Cable as Your Partner

Bringing-Ideas-Together-thumbWith over almost a century of experience fabricating and manufacturing custom wire and cable solutions for numerous industries, Consolidated knows exactly what it takes to make a great partner. Our electronic wire and cable, power supply cords, cable assemblies and other products are ideal for use in industries ranging from aerospace, agricultural, and utilities to gaming, broadcast, and home entertainment.

For a detailed look into how Consolidated fits all the requirements of a great partner and manufacturer, we encourage you to explore our company guide, Bringing Ideas Together. Inside, you will find a full list of our capabilities and how we can deliver the unique custom solution for your requirements.

choosing a wire & cable manufacturer

Choosing a Wire & Cable Manufacturer for Your Product

Nothing is worse than having a wire or cable fail on your commercial or industrial project. Not only can it mean downtime and costly repairs, but it can also ruin your reputation.  At Consolidated Electronic Wire & Cable, we know how difficult it can be to choose the exact wire for your unique applications.

Choosing-A-WireCable-Manufacturer-thumbThat is why we created a free eBook for our customers.  It is titled:  Choosing a Wire & Cable Manufacturer for Your Product. This eBook is written to help you make the right wire and cable choice. This downloadable eBook, which is available on our website, covers a wide range of topics, each of which make picking the precise wire or cable easier and more cost-efficient.

Let’s take a closer look at our new eBook, section by section.


In this section, our experts lay out the three main capabilities you should demand of your wire and cable provider which include:

  • A reliable manufacturer makes a wide range of products, and allows for customized or completely unique products.
  • A second capability that’s non-negotiable is flexible manufacturing capacity. Your wire & cable provider should be able to produce prototype runs as well as large volume orders.
  • The last capability that is important to inquiry about is the availability of comprehensive engineering services. In-house engineering support services are a must for any project, even if custom wire & cable isn’t required.


After capabilities, cost is the next crucial zone to consider when choosing a wire and cable provider. Our eBook takes you through the hidden charges you should keep an eye out for as well as tips on how to save time and money.


No matter how affordable something is, if the quality is low, it could jeopardize your overall project or application. Choosing a Wire & Cable Manufacturer for Your Product teaches you how to properly judge quality.

These tips include, checking what industrial, precision, and operational standards your manufacturer is certified in, and how to investigate the extent your supplier goes into inspecting raw materials and finished products.

Single Point Supplier

The final section deals with why you should try to find a wire and cable manufacturer that offers one-stop shopping. You need a supplier that has the manufacturing capabilities which can grow with you.

Everyone at Consolidated Wire believes that if you follow the advice laid out in Choosing a Wire & Cable Manufacturer for Your Product, you will never be stuck with subpar wire and cable again.

To download a free copy of Choosing a Wire & Cable Manufacturer for Your Product, please visit the eBook page and simply fill in the quick form. If you want to learn how Consolidated Wire can fulfill all of these demands for your next wire or cable project, please contact us directly today.


Welcome to Our New Website!

Consolidated Electronic Wire & Cable is proud to announce the release of our newly redesigned website.

ConWire-New-SiteOur new site is fully responsive, meaning all website pages now automatically resize to fit the screen of any computer, tablet or mobile device. The updated website also contains a variety of new information and resources related to our company and services—designed with the goal of making your job easier:

We encourage you to explore our new website and let us know your thoughts. If you have any questions, please contact Consolidated Electronic Wire & Cable today.

The Key Factors to Creating a Custom Cable

Purchasing cable or wire right “off-the-shelf” that fits your specific application perfectly is easier said than done. Oftentimes, this is not the case for commercial and industrial projects.

Cover_-_Custom_Cable_eBookThese are times when it helps to have an expert in manufacturing custom cables in your corner. At Consolidated Electronic Wire & Cable, we have many years of experience creating high-quality custom cables for a wide variety of applications including medical equipment, appliances, computers, and automation systems.

Because of our capabilities and expertise, we thought it would benefit our customers to release an eBook laying out what you need to know about custom cable manufacturing. Creating a Custom Cable is a detailed eBook that takes the reader through all the questions they need to have answered in order to get the best out of the custom cable manufacturing process.

When it comes to creating a custom cable there are a number of key elements and factors to consider.

  • How much do you need?:  Some suppliers can only handle certain amounts and sizes, so you need to have this locked down from day one.
  • What are your lead-time demands?:  Rush delivery usual takes a week, while regular orders might take between 7-10 weeks.
  • What are your essential cable requirements?:  These can include cable type, whether they are to be used indoor or outdoor, and exposure temperatures.
  • What kind of conductors/insulation/shielding/jacketing/filler do you need?:  There are many material choices for all of these, so you need to do your homework, or have an expert, like Consolidated Electronic, guide you through the process.
  • Do your cables need to meet or exceed certain industry standards?:  These include popular standards like RoHS, OSHA, and Mil-Spec.

All of this information and more can be found in our new eBook, Creating a Custom CableShould you have any questions afterward, please contact Consolidated so one of our custom cable experts can assist you.

To download our free eBook, Creating a Custom Cable, simply click the link or select the button below.