Cable assemblies enclose vulnerable wiring in protective sheaths and incorporate a nearly unlimited variety of connectors based on the intended use. Overmolded cable assemblies go a step beyond a simple sheath by enclosing the cable or wire and connector with overmolded material.
Cable or wire assemblies are placed within a mold, which is then injected with a pressurized molten plastic. Once the material hardens, it turns into a protective layer that seals the junction between the wires/cable and connectors to reduce the risk of damage.
Customizing your overmolded cable assemblies is the best option for ensuring your electronics are protected. They are ultimately more rugged and cost-effective because the assemblies are seamless and essentially turned into just one comprehensive piece. The overmolding process allows customization of the following:
Overmold materials. Different materials imbue the assembly with different degrees of chemical or moisture resistance, heat resistance, and more. There are a variety of common plastics available for overmolding. Polyvinyl chloride (PVC) is an inexpensive general solution, but only offers minimal protection against strong acidic chemicals. Conversely, polyethylene (PE) and thermoplastic elastomer (TPE) can withstand strong acids. Polyurethane (PU) and thermoplastic polyurethane (TPU feature good resistance to weather, aging, and other harsh environmental conditions, making them ideal for outdoor applications. Material selection is based on degrees of protection desired and compatibility with wire insulation or jacket materials.
Color. During custom projects, manufacturers can add distinct colors and resins to the molten plastic. These colors can be used to match a company’s branding, color code the assembly according to instructions or regulations, or make the equipment more aesthetically pleasing. Custom colors can improve safety and organization, as well as increase the marketability of a product.
Environmental suitability. Overmolded assemblies can be built with unique features and molded layers to protect the wires against any extreme levels of wear, stress, and abrasion that may be expected in the intended operating environment.
Regulatory compliance. Some industries maintain specific regulations regarding required levels of protection for wiring and cable assemblies. Custom overmolding processes can be customized for compliance with a variety of quality standards including IPC/WHMA-A-620 and RoHS.
Customized Overmolded Cable Assembly Applications
Custom overmolded assemblies offer enhanced strain relief and suitability for a wide range of environments. They can outlast units with multiple separate parts or thin layers of protective sheathing. Custom colors also make them ideal for complex installations or environments where visibility is poor. We’re proud to serve the following industries:
Automotive.Automotive assemblies must withstand the harsh heated environments inside vehicles, exposure to dust, and contact with chemicals. Communications. Communication wiring needs to be able to withstand harsh environmental conditions to ensure stable performance.
Home electronics. Wiring for consumers needs to be able to withstand a lot of flexing and adjustment and organizational coloring strategies make DIY installations and assemblies more appealing.
Medical equipment. Wiring for medical equipment and tools need to be able to withstand constant flexing and wear. They also need to be able to withstand continuous sanitation efforts to make them compliant with hygienic standards in hospitals.
Military and defense. Custom overmolded assemblies can withstand harsh conditions and extreme weather, use in a variety of different environments, and constant flexing. They offer an ideal solution for equipment which must operate reliably in harsh and dangerous environments in a variety of situations.
Oil and gas. Oil and gas industrial facilities, both in the processing plant and on the oil field, rely on cable assemblies for machinery and equipment that operate effectively near chemicals and constant wear and tear from harsh environmental factors.
Wind and solar energy. Alternative energy systems need robust wiring systems that remain durable in interior and exterior environments.
Industrial and OEM. Overmolded wire and cable assemblies are ideal for the harsh conditions found in industrial environments.
Consolidated Electronic Wire & Cable Solutions
When you choose custom overmolded cable assemblies, you get more than custom designs and colors. This process ensures you have a cable assembly that’s the right fit for the electronics, the environment, and the relevant regulatory standards of your operation. At Consolidated Electronic Wire & Cable Solutions, our team uses high-performance materials and expertly designed systems to create assemblies that outperform and outlast other assemblies.
Consolidated Electronic Wire & Cable is a leading medical cable manufacturer that provides custom engineered and manufactured wires and cables for an extensive range of medical applications. With more than 100 years of experience, we have established a thorough understanding of the particularly rigorous standards and regulations that apply to the medical industry. Our experts can provide quality wiring solutions tailored to meet your particular needs, and our facility is designed to create cable and wiring products that meet and exceed even the most stringent industry standards.
Medical Cable & Wire Applications
At Consolidated Electronic Wire & Cable, we offer the highest quality wiring and cable on the market. Our medical cable products can be found in a variety of medical applications, from diagnostic equipment to laboratories and lighting systems.
Medical Imaging and Diagnostics
Medical diagnostic and imaging equipment requires high-performance, reliable wiring and connections to transfer information accurately and securely. Common diagnostic and imaging systems include MRIs, PET and CT scans, ultrasounds, and X-rays. This type of equipment is critical for the diagnosis and treatment of patient injuries and illness.
Medical laboratory equipment requires medical cables and wires to ensure the accurate measurement, analysis, and monitoring of patient health. It is used to help medical professionals examine bodily fluids for signs of disease or infection. Lab equipment also includes life support equipment such as dialysis machines, cardiopulmonary bypass (CPB), ventilators, and anesthetic dispensers. It can further be used to measure and track patient vitals using EEG and ECG measurements.
Treatment Units and Operation Tables
Medical cable and wire is critical for use in treatment equipment such as surgical lasers, LASIK equipment, and medical infusion pumps. Operation tables must be equipped with reliable wire and cable arrays to ensure appropriate positioning of the patient during sensitive procedures.
In addition to accurate table orientation, surgeons must have extremely bright lighting to operate safely. This requires extremely reliable and durable wire and cable assemblies that can withstand high power levels and extreme temperature fluctuations.
As automation becomes more common in medical practice, robot-assisted surgery is helping medical care practitioners provide quick, efficient, and accurate surgical procedures. Surgical robots are highly complex and require the ability to move smoothly and quickly with a high degree of precision. A surgical robotics system will require data cables to receive and transmit instructions, as well as sensor cables to transmit critical information to the operating system in real time. These cables must be highly flexible and able to withstand bending and turning motions common in surgical robotics functions.
Electronically Adjustable Hospital Beds
Adjustable hospital beds with electronic controls make it easier for patients to enter and exit the bed comfortably and safely, and provide an easy means of adjustment for comfort. Not only does this allow patients more freedom of movement, it helps healthcare practitioners move patients with a significantly lower risk of injury due to falls. Cables in electronically adjustable hospital beds must be flexible and able to operate when bent by the bed’s movement.
Hospital Lighting Units
Hospitals require highly adjustable and specialized lighting for different applications. Lights over workstations must be bright enough for healthcare professionals to read charts, while room lighting must be adjustable. Bright light is necessary for nurses and doctors to read patient charts, insert IVs and deliver injections, but the lights should be able to dim for the comfort of the patient. Medical cables are available with a broad range of designs and fixtures to ensure optimal operation for all healthcare applications.
PA and Communication Systems for Staff
Reliable communication is crucial in a healthcare environment. From requesting emergency care to communicating patient needs, healthcare professionals must be in contact almost constantly over the course of the workday. Medical cables and wiring arrays help hospitals and other medical facilities establish clear overhead PA systems for code calls, emergency requests, and paging, as well as small communication devices that can be used for direct interpersonal contact.
Contact Us for Medical Cables & Wires
For more than 100 years, Consolidated Electronic Wire & Cable has been a proud provider of quality custom solutions for wire and cable arrays for the medical industry. We offer an extensive selection of conductive wire materials of varying lengths in both shielded and unshielded designs, with coatings and color options to suit the specific requirements of your medical applications.
Contact our experts to learn more about our medical cables and discuss your customization options.
Posted by Jason Kline on | Comments Off on Shopping for Wire & Cable With an Expert
There are lots of different cables available on the market, each suited to a specific range of applications. Finding the right one for your particular needs can be overwhelming. Understanding the specific aspects that should influence your purchasing decision can help to narrow your focus and determine the appropriate cable for your needs.
Important factors to consider include:
Knowing the particulars of your application needs in these seven areas can help you communicate effectively with a cable and wiring expert.
Information You Need
When you call or email a cable and wiring expert to find the best product for your project, having specific information at the ready will expedite the process. Before you call or start shopping, gather any requirements you have for the following areas:
Cables have between one and 100 different connectors depending on their intended purpose. If you know how the cable will be used in the future, your service provider can better determine which combinations and gauges to include, as well as what materials to use.
The environment in which the cable will handle its primary functions is one of the most important factors. The metal composition of the wire has to be able to withstand the environment, or else it will lose long-term effectiveness. For example, if you expect the cable to have a lot of outdoor usages, your service provider may recommend tinned copper wire, which can resist corrosion and oxidation. If your new cable will be used in hot environments, silver-plated copper is a better choice. Having this information from the outset ensures you get the cable you need faster.
Beyond just the choice of metal material, different cables have varying layers of exterior protection. The non-metal tubing that protects the wires or wire groups—called the jacketing—plays an important role in keeping the environment away from the wires. For weather-resistant cables, carbon blank may be combined with PVC, semi-rigid PVC, or PE jacketing. If the area is home to a lot of extreme weather, the jacketing might have polypropylene, polytetrafluoroethylene, or polyurethane layers instead.
Insulation gives wires the ability to withstand greater temperature extremes in both indoor and outdoor applications. With the right materials, manufacturers can insulate wires to keep them safe for use in environments with a temperature as low as -65° C or as high as 250° C. Insulation can also protect against non-temperature factors such as moisture and air pressure. All cables, regardless of application, must be insulated against atmospheric conditions.
Wires that are moved frequently throughout the day need a great deal of flexibility so they don’t break or wear through. You can request cabling in these three different flexibility designations: normal, flexible, and robotic-flexible. The wiring itself plays a role in flexibility by either using thick, solid strand wires with low gauges (which would be very rigid) or multiple thinner strands (which are more flexible).
Different jackets can impede or allow overall flexibility. Polyurethane is an excellent jacketing choice because it provides both strength and flexibility. If cables should be completely rigid instead, manufacturers can make them from solid conductors.
Every cable should also meet the applicable industry and safety standards. Some standards you should take note of include:
ISO 9001 (International Organization for Standardization)
RoHS (Restriction of Hazardous Substances)
NEC (National Electrical Code)
UL (Underwriters Laboratories)
CSA (Compliance, Safety, Accountability)
OSHA (Occupational Safety and Health Administration)
VDE Association for Electrical, Electronic and Information Technologies
LF (Lead Free)
Mil-Spec (Military Specifications & Standards)
Manufacturers can meet specific needs if they’re given detailed drawings. If you need to recreate a previously existing cable or have a cable rebuilt to meet more exacting standards, your wire and cabling manufacturing company can let you know about their capabilities and if they can perform the task before the project begins. They need as much detailed information as possible to make that determination. They can also address previously existing deficiencies in older cables.
Knowing your budget before placing an order or consulting with a cable manufacturing expert can help them find the right materials and processes. They can make sure you get the best possible performance within your budget.
Consolidated Electronic Wire & Cable Solutions
Consolidated Electronic Wire & Cable is a leading manufacturing company in the wiring and cabling industry and we have been developing custom cables for over 100 years. Call us today for expert assistance in finding the right materials, jacketing, and design considerations for your project.
Wire and cable not only has deep roots in industry, but it remains indispensable for many applications today. Dependable wire and cable is vital for the manufacture of components used for signalization, electrical service, and computer networking, as well as essential cable and fiber-optic cable.
There is a large number of standard wires and cables available for many applications. Still, sometimes these products are not enough to meet a customer’s specific requirements that call for the design and manufacture of a custom cable instead.
Regardless of a custom cable’s intended use, whether it is for industrial machinery, appliances, automation systems, computers, medical equipment, or other applications, it is crucial that they are manufactured to the highest levels of quality and are completed within specified turnaround times.
Many people may operate under the assumption that anything custom must be incredibly expensive and require lots of time and attention. However, with Consolidated Electronic Wire & Cable, we will help save you time, money and space at your facility with your custom wire and cable project. Here’s how:
It can be a challenge to find the right components for a cable. Unlike our competitors, we provide flexibility for custom projects that conforms to our customer needs. We will work with you on the customization of the product, volume, price, and more to ensure you have the product exactly when you need it. There’s no extra time waiting for a cable house to ship with extended lead times at their convenience and in their quantity thresholds.
Custom cables are designed with your specific application in mind for these considerations:
Indoor or Outdoor Use
Consolidated Electronic Wire & Cable’s “create your custom cable now” form quickly walks you through all the information needed to create a cable that best suits your application. Our expert team will meet the demands of your particular environment and application and will help you outline the basics of these essential implements, so you can find the perfect wiring or cable.
Consolidated Electronic Wire & Cable has the reputation of a large company with small company values. We offer the same bulk quantity discounting as the big companies because of our clout in the industry. This will reduce costs on your end while still allowing you to have a product that best fits your application and performs better than any standard option available. With us, you’ll save money without sacrificing quality and receive the same level of personalized attention to your project you’d receive from a small company.
We have the ability to hold inventory for our customers, saving you physical space, as well as money since you don’t need to worry about paying for inventory costs. It also saves you time; when you need a new product, you won’t have to worry about getting new batches manufactured all over again. Instead, we will have a fresh stock available immediately for you, so you can stay on top of your own timelines.
Since 1919, Consolidated Electronic Wire & Cable has been the one-stop shop for standard and custom wire, cable, cord set wire harnesses, and molded cable assembly. We offer smarter inventory control with warehousing and an extensive breadth of capabilities. Whether you are looking for 1,000 feet of cable or 100 feet of wire harnesses, we will easily design and manufacture a custom product for your specific application.
Consolidated Electronic Wire & Cable, a mainstay of the cable and wire industry for 100 years. As an industry leader, customers have come to expect an informed partnership, derived from experience in every major market and business segment. Quality crafted products are designed to meet customer specifications as well as regulatory standards. The Consolidated experience is one of bringing ideas together, melting an environment of adaptability and innovation with the customer in the driver’s seat!
Quality Customization Services From an Expert Provider
At Consolidated, we are committed to manufacturing and delivering quality wire and cable solutions. We offer a variety of services to ensure customers receive product solutions tailored to unique project requirements. Our primary customization services include:
Dyeing: Dyeing each wire and cable in a distinct color facilitates identification even after installation within a piece of equipment or system.
Striping: Similar to dyeing, striping allows for easier identification. Rather than adding a single solid color, the process adds spiral or parallel stripes across the length of the jacket of a wire or cable.
Labeling and jacket printing: These services provide customers with a unique branding opportunity, promoting the business by adding custom text or printing directly on the jacket.
Packaging: Our design and engineering experts can create custom packaging for a custom assembly. This service also enables customers to advertise as well as reduce time to market.
Consolidated shipping: Consolidated shipping offers customers a more cost-effective shipping option by combining multiple products into a single shipping container. This service ensures greater space utilization, reduces waste and the number of individual packages shipped.
Valued business partners have allowed us to serve our communities for a century given our relentless focus on:
Unparalleled Customer Service
We have proudly served a diverse portfolio of markets and industries across the globe with superior products and services. By calling in, customers reach one of our live representatives, a local professional who has direct access to their account details. Regardless of the requirements of the cable application or size of the order, each member of our expert team is dedicated to ensuring every customer finds cable and wire products exactly suited to their needs.
Big Company Reputation With a Small Company Values Feel
Our reputation as a trusted wire and cable company has been earned through consistency. We are able to leverage economies of scale purchasing, large-scale production capacities, and bulk inventory capabilities to offer significant savings to customers. At the same time, as our team understands the importance of strong customer relationships, they handle each account personally and on a case-by-case basis. Together, these qualities ensure that customers get the high-quality products and cost savings expected of a large company with the intimacy and level of service typically characteristic of a small business.
Significant Cost Savings
Save time, save space, save money. We have the availability of a distributor and the flexibility of a manufacturer—as we hold product inventory and offer customization services—which allow us to tailor our solutions to what our customers need and have them available when needed most.
Enjoy a one-stop shopping experience–sizes, lengths, applications. Bulk wire and cable or wire harness assembled to meet targeted demand. We keep high-turn items on hand, available when you need it. Need a year’s worth of a custom product? We can build it, we can stock it.
As an ISO 9001 and QS 9000 certified company, we work hard to ensure that our products meet each customer’s unique requirements and all applicable regulatory standards. To ensure adherence to these specifications, we subject every aspect of an operation to rigorous inspection, testing, verification and continual improvement based on changing customer and industry demands. Additionally, we comply with RoHS requirements by checking all raw materials utilized before, during, and after every manufacturing operation.
Convenient Distribution Center
Our modern, large-scale distribution center is minutes from Chicago’s O’Hare International Airport, which enables us to ship products quickly and efficiently!
Choose Consolidated for All Cable and Wire Needs
Consolidated supplies customers the highest quality cable and wire solutions with expert service, customized solutions, and transparent pricing. By committing ourselves to excellence, dependability, and innovation, we have become an active and lasting leader in the wire and cable industry. For more information about our products and services, contact us today. We are looking forward to serving you!
Private labeling involves the manufacturing of a product or item by one company for another, after which the second company sells the product under its name or brand. Many large corporations rely on private labeling if they don’t have an in-house manufacturer for a certain part or product. As a result, they can ensure that their components are manufactured correctly and cost-effectively while staying true to their brand.
The advantage of private labeling is that a company can obtain an essential component for a low cost without having to add additional facilities or staff. It also gives the company greater control over production and branding, since it has the ability to make changes whenever necessary. Most importantly, by using a manufacturer who specializes in a particular field or area, companies can be sure that they’re receiving the highest-quality product available, which in turn increases the quality of their overall product, device, or system.
Private Solutions with Public Benefits
While private labeling has taken off in numerous industries, it’s become particularly popular among industries and companies that depend on cables and other electronic devices. Many of Consolidated Wire’s clients, for example, are communications companies that need specialized cables for their products or internal infrastructure.
By closely collaborating with a manufacturer, a company can develop a cable tailored to its specific needs without spending the large sums needed to hire and train an in-house manufacturing team.
In recent years, Consolidated Wire did just that by helping a client in communications develop customized manufacturing retractile cords with custom DIN connectors. When the customer came to us with specific requirements, our team reviewed its specifications and then used precision over molding to craft the cables. Using custom tooling over the mold, we then manufactured the DIN connector with strain relief and used polypropylene as the base material.
This collaboration resulted in lasting solutions to pressing challenges. After performing full quality control procedures to test its functionality and performance, our team provided the client with a custom 12-inch retractable cord that can extend to a full 60 inches. Today, we manufacture thousands of these custom cords for the company in only a few weeks.
Counting on Consolidated Wire
For more than 100 years, Consolidated Wire has provided custom cable solutions for clients in every major industry. Backed by our well-honed expertise in cable building and state-of-the-art facilities, we’re able to create custom cables for any customer who might need cables but doesn’t have the manpower or facilities to manufacture them independently. With the continued rise of private labeling, we are ready to supply any company with specialized solutions to their manufacturing challenges.
As leaders in private labeling, we pride ourselves on our versatility. Offering a wide array of building materials, we’re able to modify the flexibility, insulation, jacketing, and sheathing of our products according to your needs. In addition, we can fill everything from small orders of a few hundred cables to large bulk orders. Regardless of your field, we have the experience and resources needed to identify an ideal solution for your business.
With our wide-ranging capabilities and sterling reputation within the industry, Consolidated Wire can meet almost any specification for any application. If you’re interested in learning more, contact us today to begin creating your own private label cable.
At some point in the distribution process, many of today’s most critical industrial parts and products end up in a warehouse, also referred to as a distribution center. These spaces are specifically designed for the safe, efficient storage and handling of products, parts, and materials.
Rather than just stuffing goods away haphazardly, utilizing well-thought-out warehousing techniques can make a huge difference in terms of both time and money.
The Benefits of Using a Warehouse
There are a number of advantages to keeping supplies in a warehouse. Having products organized and easily accessible allows them to be sent out at a moment’s notice, as companies are able to maintain smart inventory control. This ensures that a business won’t run out of certain products, leaving clients in a bind for emergency or rush orders.
Some goods move slowly, while others go out very quickly. All of these products have to move, however, which means they need to be laid out and handled based on how they are expected to move through the system.
With the proper setups in place, warehouses can allow for a more profitable return on investment (ROI), as buffer inventory can be maintained to smooth out fluctuations in supply and demand. This builds up investment stocks, keeps down overtime charges, and allows a company to buy and stock supplies when prices are more favorable.
Why You Should Choose a Single-Point Supplier
To enhance these benefits, you should try to partner with a manufacturer that offers one-stop shopping. At Consolidated, we manufacture a wide range of cable and wire products and can create customized, unique products while offering convenient, timely distribution. As flexible manufacturers, we can handle prototyping runs as well as large-volume orders, and offer in-house engineering support services.
No matter the size, complexity, or application of your cable installation, a one-stop source with centralized distribution will have manufacturing capabilities that can grow as your company does. Centralizing your wire and cable provisions not only simplifies administrative tasks, it also saves you time and money.
With so many different types of cables on the market, it can be a challenge to find the perfect cable for your application. With some knowledge of your application’s demands, however, you can quickly narrow down your options and find the ideal solution for you company. To simplify your search, we’ve covered some of the key aspects to consider before investing in a cable.
Cable Use How you plan to use your cable will determine how many conductors you’ll need within it. Depending on their use, cables can contain as few as one conductor to as many as 100. These conductors are available in a variety of combinations, gauges, and building materials, all of which are better suited to certain applications. Tinned cooper wire, for example, is an excellent choice for cables located outside because of its high resistance to oxidation. Similarly, silver plated copper wire works well in particularly hot climates because of its corrosion resistance.
Weather All cables require proper insulation against typical atmospheric conditions, including temperature, moisture, and air pressure. A qualified manufacturer like Consolidated Wire can provide you with an appropriate material for your application. Some of our most popular and versatile materials include:
Polyvinyl chloride (PVC), an inexpensive and easy-to-use insulator that resists flames, abrasion, moisture, gasoline, acids, solvents, and ozone
Semi-rigid PVC, a strong insulator against acid, water, heat, and alkalis
Polyethylene, an inexpensive plastic known for its strong electric qualities and resistance to soldering, solvents, cutting, and cracking
Flexibility A cable can be more or less flexible depending on its typical movements over the course of the day. Most wires are available in normal, flexible, or robotic-flexible versions. The type of jacketing chosen for your cables can also have an effect on their flexibility. Polyurethane jacketing, for example, provides a much higher level of strength and flexibility than other materials.
Indoor/Outdoor Use Outdoor cables generally require greater protection from the elements than their indoor counterparts. A number of jacketing materials can afford the necessary level of protection. Consolidated Wire’s PVC, Semi-Rigid PVC, and PE jacketing, for example, all provide excellent weather resistance when complemented with Carbon Blank. Our polypropylene, polyurethane, polytetrafluoroethylene jacketing offer excellent resistance to foul or extreme weather, as well.
If you have any additional questions about cables, the experts at Consolidated Wire are here to help. With more than a century of experience in developing customized wire and cable solutions, we have the expertise needed to determine which materials and components will best fit your application. Download our “Creating a Custom Cable” eBook today for a more detailed overview of cable customization.
In our digital age, nearly every device needs to be powered with some type of cable or wire. With such a diverse set of gadgets, appliances, and tools at our fingertips, however, it’s hardly surprising that there isn’t a single cord or cable for all of our electronic devices.
Whether it’s medical equipment, a computer, an automation system, or a car, most personal and professional applications need a cable of a particular length or size that can perform at a certain level and withstand unique environmental conditions.
In cases where a standard cable just won’t cut it, customized cables can provide the unique fit and functionality for your specific application.
Finding the Perfect Cable
It can be a challenge to find the right components for a customized cable. Prospective customers need to take an array of factors into consideration, including the desired cable dimensions, the expected environmental conditions, level of flexibility required, temperatures it needs to withstand, and whether it will be used outside or inside.
If you’re armed with answers to these questions, however, a trusted cable and wiring company like Consolidated Wire can determine the kind of materials needed to build the ideal cable for your company. At every stage of the process, a talented team of designers and engineers can work closely with you to identify the best materials for your cable and develop a design that’s suited to your typical applications. As soon as you’ve settled on a design, you can expect to receive your order in three to ten weeks.
Working with Consolidated Wire
Since 1919, Consolidated Wire has specialized in creating customized wiring and cabling solutions for customers in a broad range of industries. Widely respected for our versatility and deep commitment to customer service, we design and manufacture products for nearly any application.
Our website features an easy-to-use form that allows customers to enter the information we need to build the perfect cable for you. With a wide array of materials at hand, we can adjust the strength and flexibility of your cables as needed. We also offer various conductors, jacket components, materials, insulating compounds, and fillers to help you ensure that your cable meets your exact specifications.
To learn even more about how to create your own custom cable, download our guide, Creating a Custom Cable today. If you’d like to explore working with Consolidated Wire, contact us today.