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Custom Cable Assembly Manufacturing

Cable assemblies play a vital role in the operation of electrical and electronic equipment in every industry. From simple home computers to complex manufacturing units to state-of-the-art communications systems, they create integral connections between equipment components and other equipment. Given the broad range of applications, different types of cables have been developed to meet various needs. While there are standard cables available for a wide variety of common applications, they may not always meet the requirements and restrictions of highly specialized applications. In these cases, a custom-designed and -built cable assembly is necessary.

A quality custom cable assembly necessitates careful evaluation and selection of numerous elements. That’s why it is important to work with an experienced cable assembly manufacturer since they will have the knowledge and skills needed to ensure the cable you receive fully meets your specifications.

Equipped with over 100 years of experience designing and manufacturing cable and wire solutions for unique applications and to stringent industry standards, Consolidated Electronic Wire & Cable is the ideal partner for nearly any custom cable assembly need. Our team works closely with customers on designs to create quality solutions for their cable assembly challenges. We ensure they receive the exact type of cable they need for safe and effective equipment operation.

Key Considerations for Your Custom Cable Assembly

There are numerous factors that need to be considered when designing a custom cable assembly to ensure it operates and performs as intended. Below, we highlight some of the key considerations.

Conductor Size and Color

Conductor Size and Color

Conductors are at the core of a cable assembly. A good manufacturer partner should have a range of options available so they can meet various customer requirements and restrictions. For example, they may offer conductors ranging from 4 to 28 AWG configured in one to 60 pairs.

The cable assembly experts at Consolidated Electronic Wire & Cable can make cable assemblies with many types of conductors. Additionally, we can use different industry-standard colors or patterns to facilitate tracking and identification.

Stranding

Stranding

Stranded wire consist of thin conductive wires twisted into a bundle and compressed and insulated with non-conductive material. Compared to solid wire, it offers greater flexibility and malleability, which is why it is often used to connect electrical and electronic components in tight spaces. The individual wires can be as small as 0.002 inches or as large as 0.01 inches and made from bare copper, tinned copper, or silver-plated copper, depending on flexibility and conductivity requirements.

  • Conductor Size and Color
    Conductor Size and Color

    Conductors are at the core of a cable assembly. A good manufacturer partner should have a range of options available so they can meet various customer requirements and restrictions. For example, they may offer conductors ranging from 4 to 28 AWG configured in one to 60 pairs.

    The cable assembly experts at Consolidated Electronic Wire & Cable can make cable assemblies with many types of conductors. Additionally, we can use different industry-standard colors or patterns to facilitate tracking and identification.

    Conductor Size and Color
  • Stranding
    Stranding

    Stranded wire consist of thin conductive wires twisted into a bundle and compressed and insulated with non-conductive material. Compared to solid wire, it offers greater flexibility and malleability, which is why it is often used to connect electrical and electronic components in tight spaces. The individual wires can be as small as 0.002 inches or as large as 0.01 inches and made from bare copper, tinned copper, or silver-plated copper, depending on flexibility and conductivity requirements.

    Stranding

Conductor Insulation

Insulation serves a number of purposes in cable assemblies. For example, it protects the wires from environmental compounds and conditions, prevents electrical leakage, and separates conductors from one another, all of which are essential to keeping the cable assembly working effectively and safely.

There are many insulation options available, each of which offers different advantages for particular applications. Some of the most commonly used are:

  • Polyvinyl Chloride (PVC): an economical and easy-to-use material exhibiting good resistance to abrasion, chemicals, flame, moisture, and ozone
  • Semi-Rigid PVC (SR-PVC): an abrasion-resistant material known for its insulative properties against acids, alkalis, heat, and water
  • Polyethylene (PE): an affordable material with excellent electrical properties and high resistance to cracking, cutting, soldering, and solvents (when cross-linked)
  • Polypropylene (PP): a material suitable for use in temperatures ranging from -30° C to 80° C
  • Polyurethane (PU): a material commonly used as jacketing in high-stress environments (e.g., with low temperatures or salt spray) due to its toughness and flexibility
  • Polytetrafluoroethylene (PTFE): a material characterized by its flexibility, broad temperature suitability (-73° C to 204° C), and chemical, heat, oil, and water resistance
  • Polyvinylidene Fluoride (PVDF): a versatile material used in a range of industries due to its high flexibility, light weight, and durability (resistance to abrasion, chemicals, fire, heat, and weather)

Fillers

As the name implies, fillers are used to fill the space within the cable to create the desired shape. The filler material used is matched to the application to ensure it is suitable for the expected operational and environmental conditions. Examples of typical fillers include cotton, nylon, paper, and polypropylene.

Wraps and Shields

In certain situations, cable assemblies must be shielded or wrapped. Shielding and wrapping material protects the cable assembly’s components from damaging operational and environmental conditions and the purity of the signal from interference.

The type of material used depends on what the cable assembly needs to be protected against. Some of the options available include:

  • Mylar Foil Wrap: Mylar foil wrap is one of the most commonly used materials for shielding and wrapping applications. It is lightweight, inexpensive, and suitable for high-frequency RFI applications.
  • Braided Wire: Braided wire is the most traditional form of shielding. It is made from tightly woven wire, which produces a versatile, strong, and flexible material suitable for encapsulating shielded cable assemblies.
  • Spiral Serve Wire: Spiral serve wire consists of wire wrapped in one or more layers around insulated conductors. It is easy to terminate and effective for low-frequency protection applications.

Jacket Materials

The jacket is the outermost layer of insulation around a cable. Its main purpose is to keep moisture out of the cable. However, it also affects the cable’s flexibility. It can be made from the same materials as listed in the insulation section. PVC is ideal for applications where low cost is critical, PE is suitable for outdoor environments, and PU is perfect when high strength and flexibility are required.

Cable Types

Cables are available in many standard variations. Custom cable assembly designers and manufacturers can use the standards as a starting point for more complex solutions, which helps save time and money. We offer a variety of cable options to suit different customer specifications, including with regard to conductor combinations (e.g., single, multi-, and multi-paired) and quantities (1 to 100+).

Why Partner With Consolidated for Your Custom Cable Assembly Needs?

Looking for custom cable assemblies for your next project? Consolidated Electronic Wire & Cable is the ideal partner! By choosing us, you benefit from our:
Extensive experience

Extensive experience

We’ve developed quality cable and wire solutions for customers across a wide range of industries for more than 100 years. This experience provides us with the knowledge and skills we need to create cable assemblies for nearly any application. We can tailor the cable assembly’s length, color, insulation, jacketing, and more to suit the specific needs of the customer. Whether a customer requires 5,000 feet or 1,000 pieces, we can develop and deliver an appropriate custom cable assembly solution.

Commitment to quality

Commitment to quality

We are dedicated to producing cable assemblies that meet even the most rigorous quality standards. We maintain ISO 9000:2015 certification and keep all of our operations consistent with the latest industry and government regulations, so customers can trust that their solution will always meet or exceed compliance requirements.

Superior customer service

Superior customer service

We work closely with each customer to find the right solution for their project needs. By maintaining open lines of communications, we ensure all cable assembly considerations are correctly addressed.

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