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HomeTips & GuidesCable Fabrication: What are the Important Factors for Customs Cable Designs

Cable Fabrication: What are the Important Factors for Customs Cable Designs

Designed to meet specific functions unique for some particular application, customized cable fabrication is essential for the overall performance of any electric or electronic device.

However, when it comes to custom cable fabrication or cable assemblies, it is essential to meet all protocols and quality standards apart from ensuring safety. 

So, let us study all the things you need to keep in mind for custom cable fabrication.

Table of Contents

Cable Materials:

To ensure the best performance and functionality for your custom cable assemblies, you must use high-quality materials in their fabrication. 

If the products are of poor quality, the cables will underperform, irrespective of the design. 

Further, you may face some safety issues, including electrical sparks that release smoke and toxic fumes. Also, there may be sparks that lead to fire, combustion, or deflagration.

 Sometimes, all these issues may cause irreparable damage to the product.

The quality of the components used in the custom cable fabrication decides the overall quality of the cables. 

There are several cable assemblies, such as ethernet assemblies, power cable assemblies, RF assemblies, custom wire harnesses, fiber optic assemblies, or molded assemblies.

 All these assemblies require quality in their conductors, connectors, sheathing, shielding, and others.

Conductors:

The conductor used in a custom cable assembly depends on its applications. 

Copper’s mechanical properties (ductility, durability, and malleability) and conductive properties are far better than other conductors, and thus it is very common.

 Sometimes, manufacturers also use copper-clad steel or copper alloys in some applications. However, this is mostly when the break strength of pure copper conductors becomes an issue.

Sheathing:

The sheathing material used in any cable ensures the safe use of that cable in the particular application. 

Manufacturers decide the sheathing design based on the insulator type. 

Further, sheathing may also change for applications requiring thermoset and thermoplastic material.

Shielding:

Cable shielding helps in controlling radio frequency interference and electromagnetic interference in cables. 

RFI and EMI are the two significant issues that put the device’s safety at stake. 

These interferences hinder signal transmission, leading to the malfunctioning of the devices. Manufacturers chose shielding based on the application requirements.

 Some common shielding options include metal foil, electronic housing, braided shields, or combustion of foil and braid shields (best for EMI protection).

Different kinds of cable construction with varying material 

Different kinds of cable construction with varying material 

Cable Connectors:

Connectors are also a critical part of a custom cable design. Excess stress on the connectors may lead to their failure. As a result, the cable may not function as desired. Manufacturers pick the cable connectors based on the type of signal getting transmitted through the cable.

 Cable designers lessen the stress points to provide stress relief, thus preventing termination failure.

Different kinds of connectors

Different kinds of connectors

Cable Testing:

One of the best ways to ensure the safety of the cables and their functioning is through testing. 

Several electrical safety testing procedures examine products for their 100% reliability. 

Some of these tests are the VSWR test, continuity and resistance test, and Hipot test

All these tests can quickly identify any mis-wired or defective before its installation. 

Further, engineers and designers also find intermittent connections, open shorts, resistance threshold, and contact isolation. 

All these identifications ensure that the best and safest product reaches the consumer.

Certifications:

Certifications earned by a manufacturer on his products give you a guarantee of quality. 

Such certifications also prove that the manufacturer has followed industry standards during cable fabrication. 

Some popular certifications related to custom cable fabrication are ITAR certification, ISO 9001, UL and CSA registration, IPC-A-620, and WHMA membership.

Among these certifications, UL/CSA and ISO are the main. 

A UL/CSA-registered product ensures that the products meet all industry standards and are safe.

ISO stands for International Organization for Standardization. This is a standard defining condition for quality management systems for organizations, companies, and businesses.

Conclusion:

To design a safe and functional custom cable assembly, manufacturers must focus on every single step in their manufacturing. 

Manufacturers keep in mind industry standards and safety protocols for everything, be it the materials, process, testing or production. 

If you want high-quality custom-cable assemblies, Cloom is the best choice for you. We have been in the custom cable fabrication business for years now.

Our engineers design superior-quality wiring harnesses and cable assemblies meant for varied applications.

Hi I am Christa, sales manager of Cloom.

I have extensive expertise and experience in wiring harnesses and I believe I can help you.

And we have a very professional technical team who can clearly understand the customer’s needs and give professional suggestions and solutions after receiving the drawings.

If you also have wiring harness needs, please send me the drawing so that we can give you our quote and start our business.

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