creating a custom cable - thomasnet · 2019-10-25 · a mylar wrap usually made of foil is one of...

Wire and cable have a very deep history in industry, and remain indispensable for a wide variety of applications today. In our current digitized and online landscape, getting the best wire and cable is more important than ever. There are a large number of standard wire and cable available for many applications, but sometimes these products are not enough to meet a customer’s specific requirements—and this is when they need custom-designed and custom-built cables.

No matter where custom cables are needed, whether it is for business machines, medical equipment, appliances, automation systems, computers, or other applications, it is important that they meet the highest levels of quality and are completed within specified turnaround times. There are a variety of elements that make up quality custom cables and many factors that must be considered. By working with an experienced manufacturer, customers can specify the exact type of cable they want to safely and effectively achieve their goals.

There is one basic question every customer needs to address when creating custom cable: how long does it need to be? It is important to find a wire manufacturer that will accommodate a wide range of lengths, and remember that many suppliers have large minimums for custom wire. If a customer requires a full production job for a large amount of cable, this is never a problem. However, clients in the market for custom-made cable often need prototypes or small production runs before committing to a larger order. Finding a company that will produce prototypes and smaller production runs will aid companies that are still working in the design phase for their cable. The right supplier can realize the designer’s exact needs, whether they are looking for 1000 or up to 1,000,000 feet of cable.

Creating a Custom Cable

“ It is important to find a cable manufacturer that will accommodate a wide range of custom lengths, as many suppliers have large minimums for custom cable.”

3Toll Free: 800.621.4278 | Fax: 847.455.8837 | www.conwire.com | Contact Us

Wire and cable not only has deep roots in industry but it remains indispensable for a wide variety of applications today. In our current digitized and online landscape, getting the best wire and cable is more important than ever. There is a large number of standard wires and cables available for many applications, but sometimes these products are not enough to meet a customer’s specific requirements—and this is when a custom-designed cable is needed.

No matter where custom cables are needed, whether it is for industrial machines, medical equipment, appliances, automation systems, computers, or other applications, it is important that they meet the highest levels of quality and are completed within specified turnaround times. There are a variety of elements that make up quality custom cables and many factors that must be considered. By working with an experienced manufacturer, customers can specify the exact type of cable they want to safely and effectively achieve their goals.

There is one basic question every customer needs to address when creating a custom cable: What length will be needed? It is important to find a cable manufacturer that will accommodate a wide range of lengths, as many suppliers have large minimums for custom cable. If a customer requires a large amount of cable, this is never a problem. However, clients in the market for custom-made cable often need prototypes or small production runs before committing to a larger order. Finding a company that will produce prototypes and smaller production runs will aid companies that are still working in the design phase for their cable. A good supplier can build to the designer’s exact needs, whether they are looking for 1,000 to 1,000,000 feet of cable.

http://cables.conwire.com/contact-us?&__hssc=185625462.1.1407173404815&__hstc=185625462.62916b12f8147fef36a5a465450d8fab.1396037758516.1406916520602.1407173404815.106&hsCtaTracking=4a664faa-ae55-4065-a06e-4a90a98ffd19%7C87f15489-9f29-48eb-965e-825c8786aa5a


LEAD TIMESTurnaround times for constructing custom cable depend on the complexity of the job and the urgency of the customer’s need. Depending on the supplier, rush custom orders can be completed in as little as one week. Typical timeframes for non-rush orders often range from 5 to 10 weeks.

ESSENTIAL CABLE REQUIREMENTSCustom cable has a wide range of characteristics and properties you need to consider when specifying an order for custom work. All of the following need to be addressed:

Cable Type: A good manufacturer will offer a variety of conductor combinations in cable including single, multi-conductor, and multi-paired constructions. Depending on need, cable can be fabricated from 1 to 100+ conductors.

Temperature: Depending on operating conditions, wire and cable often need to withstand a wide range of temperatures. Using the proper insulation, a supplier can provide custom products that can handle temperatures from -65°C up to 250°C.

Flexibility: Different applications require different levels of flexibility. Wire and cable can be constructed from solid conductors if they need to be rigid, or can use a large number of small gauge strands for higher levels of flexibility. Many different levels of flexibility are available with some of the more common types being normal, flexible, and robotic-flexible.

Indoor/Outdoor Use: The location of the cable/wiring application will always play a large role in obtaining the optimal design, as it must be able to successfully withstand its environment for long-term performance. When creating a custom cable that will be used outdoors, features such as UV-protection and moisture-protection should be considered.


“ A good cable supplier will have all the conductor options that a buyer could need to make the best choice for any given application.”


CONDUCTORSAt the core of cable construction are the conductors. A good supplier will have a variety of conductor options such as single, pair, and triad configurations, and offer a number of different gauges. These often run from four to 28 AWG (American Wire Gauge), and can include cables from one conductor to 60 pairs. Customers also need to have a full range of different material types to choose from, allowing them to find the most appropriate conductor to fit their exact specifications.

Material Types: • Bare Copper Wire (Annealed Bare): This is the most basic type of wiring that has been

used in various settings since the early 19th century. It is still widely used today and generally shows good corrosion resistance, but one consistent concern in using this wire is its vulnerability to oxidation.

• Tinned Copper Wire: The tinning process protects copper wire from oxidation and allows the wire to be soldered, making this a popular choice for conductors.

• Silver Plated Copper Wire: For this material, highly conductive copper wire is further protected from corrosion by its silver coating. It is also ideal for use where it will be exposed to high-temperatures.



INSULATIONInsulation is imperative in wire and cable products. It consists of non-conductive materials that keep the wire working safely and effectively. Insulation protects the integrity of the wire against environmental conditions such as heat, radiation, and water. It also prevents electrical leakage and keeps the wire’s current separate from other conductors. For any given application there are a wide variety of insulation types available, each with its own unique advantage. The following are just a few examples of the many insulators available for custom cables.

POLYVINYL CHLORIDE (PVC): PVC is an economical and easy-to-use insulator with good resistance to flame, abrasions, moisture, gasoline, acids, solvents, and ozone.Temperature Range Centigrade:-55°C to +105°C Insulation Resistance: Good Weather Resistance: Excellent

Voltage Breakdown: Good Abrasion Resistance: Good Solder Resistance: Good

Capacitance: Fair Non-Flammability: Good Flexibility: Good

SEMI-RIGID PVC (SR-PVC): Abrasion resistant, SR-PVC is also well known for its insulation qualities against acid, water, heat, and alkalis.Temperature Range Centigrade:-60°C to +80°C

Insulation Resistance: Excellent Weather Resistance: Excellent**

Voltage Breakdown: Excellent Abrasion Resistance: Good Solder Resistance: Poor

Capacitance: Excellent Non-Flammability: Poor Flexibility: Fair**With the addition of Carbon Blank

POLYETHYLENE (PE): This insulation is often found in coaxial cables because of its affordability and excellent electric qualities. PE can also be cross-linked, producing insulation that is highly resistant to soldering, solvents, cutting, and cracking.Temperature Range Centigrade:-60°C to +80°C


Voltage Breakdown: Poor Abrasion Resistance: Poor Solder Resistance: Poor

Capacitance: Excellent Non-Flammability: Poor Flexibility: Fair**With the addition of Carbon Blank



INSULATION (CONTINUED)

POLYPROPYLENE (PP)Similar to Polyethylene, PP can cover a wide temperature range. Temperature Range Centigrade:-20°C to +105°C Insulation Resistance: Excellent Weather Resistance: Excellent

Voltage Breakdown: Excellent Abrasion Resistance: Excellent Solder Resistance: Good

Capacitance: Excellent Non-Flammability: Poor Flexibility: Poor

POLYURETHANE (PU)Extremely tough and flexible, PU is used in many high-stress areas, including salt-spray exposure and low-temperature military applications, and is generally used for jackets only. Temperature Range Centigrade:-60°C to +80°C


Voltage Breakdown: Excellent Abrasion Resistance: Excellent Solder Resistance: Fair

Capacitance: Excellent Non-Flammability: Poor Flexibility: Excellent**With the addition of Carbon Blank

POLYTETRAFLUOROETHYLENE (PTFE)PTFE is well-known for its wide temperature range. It is resistant to water, chemicals, oil and heat.Temperature Range Centigrade:-90°C to +250°C

Insulation Resistance: Good Weather Resistance: Excellent


Capacitance: Fair Non-Flammability: Good Flexibility: Excellent

POLYVINYLIDENE FLUORIDE (PVDF)Lightweight and flexible, PVDF is used in a diverse array of industries. It is heat, weather, chemical, fire, and abrasion resistant. PVDF cables meet various standards that make them ideal for use in a building’s air circulation space. Temperature Range Centigrade:-100°C to +150°C

Insulation Resistance: Good Weather Resistance: Good


Capacitance: Fair Non-Flammability: Good Flexibility: Good


“Whether clients need prototypes, preproduction samples, or full-length production runs, a trusted custom cable manufacturer can meet customer specifications within reasonable timeframes and offer expert design assistance whenever needed.”


SHIELDINGShielding plays a vital role in preventing noise and maintaining the purity of signal in cable systems. The shielding that surrounds a cable’s conductor will protect against various types of interference, including crosstalk, static, common mode, and magnetic noise. The materials used in the shielding are determined by the types of noise to protect against. A mylar wrap usually made of foil is one of the most economical and common materials for shielding. Other commonly used shielding materials include braided wire, spiral serve wire, and EMI/RFI shielding.

JACKETINGThe cable jacket is the outermost layer of insulation. It not only protects against external elements such as moisture, but it also plays an important role in the overall flexibility of the cable. Many of the same materials listed as insulation above also may be used for jacketing. Polyvinyl Chloride (PVC) is the least expensive variety. Polyethylene (PE) is also popular, and is generally used for outdoor applications, while Polyurethane (PU) jacketing offers a high level of strength and flexibility. Pressure extruded jackets will ensure a uniform cable shape while providing added electrical performance and stability.

FILLERFillers are added during the cabling process to maintain a round shape. The contents of the filler must also meet the requirements for the specific environment of the application, including water or heat resistance. A few common fillers include Polypropylene (PP), nylon, paper, and cotton.



STANDARDSCustom manufactured wire and cable needs to meet the most up-to-date industry andgovernment standards. Some of the required and recommended standards include ISO 9001 (International Organization for Standardization), RoHS (Restriction of Hazardous Substances), CE Mark, 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), and Mil-Spec (Military Specifications & Standards). When choosing a company to create custom wire and cables, it is vital for customers to ensure that all the necessary standards will be fully met.

CUSTOM CABLE FOR ALL NEEDSNo matter what a customer’s specific requirements may be, there are custom cable options to fulfill them. Wire and cable can be created in almost any length with a wide variety of flexibility, conductors, jacket components, insulating compounds, and fillers to meet almost any specification. The above information can help serve as a valuable tool in learning the different options for custom wire and cable. If more information is needed, do not hesitate to contact a professional in the field. Whether clients need prototypes, preproduction samples, or full length production runs, a trusted custom cable manufacturer can meet the customers’ exact specifications within reasonable timeframes and offer expert design assistance whenever needed.

ABOUT CONSOLIDATED ELECTRONIC WIRE & CABLEFor more than 90 years, Consolidated Electronic Wire & Cable has been the complete source for standard and custom wire, cable, cord set wire harnesses and molded cable assembly. Whether you are looking for 1,000 feet of cable or 100 feet of wire harnesses, we can easily design and manufacture a custom product for your specific application. Our convenient one-stop shopping capabilities allow us to fulfill all of your wire and cable needs, thereby saving you time and reducing costs.


creating a custom cable - thomasnet · 2019-10-25 · a mylar wrap usually made of foil is one of...

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