Most of us have probably come across cable assemblies before, where cable groups are bundled into a single unit. Many manufacturers choose to use these assemblies for quicker installations. But what exactly makes them so popular and useful?
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This article will look at the benefits of custom cable assemblies, and maybe you&#;ll find that they could also be right for you.
What is a Custom Cable Assembly?
Let&#;s first have a look at what a custom cable assembly is. Cables are insulated electrical conductors bundled inside EMI shielding, with an outer sheath to protect them. Many companies make and use standard cables, with their lengths, sizes, colours, and constructions following industry standards, which, in many cases, is perfectly fine.
But if you are looking for superior performance, you will have to go one step further, and with that, we enter the world of custom cables. These cables are specifically engineered to meet the demands and requirements of the respective application, the right size and weight. They will be made from the best materials for the performance requirements and conditions they will be used in, including the ideal connectors.
A custom cable assembly can consist of both standard and custom cables. Still, they are bundled per your specifications to give you precisely the types and sizes you need for your installation or project. This will guarantee you a significantly better performance than mass-produced products.
What are the Benefits of Custom Cable Assemblies?
One of the most significant benefits of custom cable assemblies is that you will get the ideal performance for your application. You can get precisely what you need by picking and choosing the best cables, materials, and combinations. You will not have to compromise by having to accept certain cables that don&#;t really fit your needs if you want others that do.
The chance to pick and choose which materials you will require for your specific application will also improve the product&#;s performance. For example, the manufacturer can source the appropriate materials per your specifications if you have particular requirements for high or low temperatures, potential exposure to chemicals, or electromagnetic interference.
Due to the stringent manufacturing process, you can also benefit from far higher quality control than with standard, off-the-shelf assemblies. Generally, custom assemblies undergo rigorous testing to ensure the required functionality and quality. Whether you need specific electrical parameters, tolerances, temperature performance, or resistance to chemicals or abrasion, the cable manufacturer can provide you with all required certifications.
You can also test prototypes in a real-life environment where the custom cable assembly will ultimately be used. This way, if any attributes are not entirely up to standard, they can still be corrected before proceeding into the production stage.
A custom cable assembly allows you to combine several types of cables within one assembly, reducing the requirement for multiple cables. This eliminates unsightly cables and reduces the risk of damage.
Custom cable assemblies also allow you to order the exact number of cables required for your project or application, so you will not have much extra cable lying around.
To minimise the risk of errors and speed up the assembly or installation, you can have the cable sheaths colour coded per your specifications.
At first glance, picking standard, off-the-shelf cables and using them to connect your equipment may seem like the cheapest and fastest way to get what you need. While this may be true for basic applications, things look slightly different once you enter more specialised or high-performance environments. Retrofitting standard cables to custom cable assemblies will take time and money that you could have invested into a perfect custom setup in the first place.
Using higher-quality materials and the more stringent quality control of custom cable assemblies will save you money in the future by not having to replace the assemblies as often. Especially if your application has specific requirements, such as harsh environments (like UV light, temperature, ozone, chemicals, etc.), this can dramatically increase the lifespan of your assemblies.
Using custom cable marking, you can raise brand awareness for your clients and customers by having a direct reminder of your name and image on the custom cable assemblies you are using.
Also Read: Why Cable Assemblies Matter for OEMs & Commercial Markets
Applications of Custom Cable Assemblies
Custom cable assemblies are used in various applications, each with its specifications, regulations, and requirements.
Space and weight are among the most valuable commodities in the aerospace industry. Custom cable assemblies allow you to get all necessary cables assembled into one bundle, saving space and eliminating unneeded cables from an assembly, and getting the exact length required can also save a lot of weight.
Military-grade custom cable assemblies must withstand some of the most demanding environments and conditions imaginable, whether extreme temperatures or water and mud; it&#;s critical that any assembly is up to any condition. They must also have exceptional EMI protection and resist even extreme vibration without any risk of disconnection.
Medical environments come with their own challenges, such as aggressive cleaning agents and machinery that emits electromagnetic impulses, radiation, and more. So, the shielding has to be exceptional to ensure consistent signal integrity.
In telecommunications, it is often the quantity of cables required that makes it challenging, so being able to bundle top-quality cables together, with simple but efficient connectors can ensure the speed, quality, and integrity of the signals.
In an industrial setting, cables have to withstand various challenges, whether EMI potentially causes disruptions, abrasive conditions, or the requirements to bend and fit into their environment. Custom cable assemblies can give you the shielding and flexibility required to maximize performance and lifespan.
Like aerospace, the automotive industry faces similar challenges, such as space and weight. From the dashboard to the engine, custom cable assemblies give you the precision and efficiency required to ensure optimal performance.
Conclusion
Whether you are looking for superior performance, assured quality, increased efficiency, or look to save time and money, different types of custom cable assemblies will be the answer to your questions.
Tevelec is a market leader in different types of industrial cables for all industries in Toronto and the GTA. Since , we have been a leading cable supplier and distributor in North America, providing competitive pricing and excellent customer service.
Contact us at 905-624- today to find out how we can help you find the right custom cable assembly for your application!
The global network patch cable market is forecasted to reach nearly $9 billion by , growing at a compound annual growth rate of over 10% from its $3.4 billion value in . This is primarily driven by the 5G network build-up, installing cables in everything from cell towers to ever-expanding data centers.
This article addresses all aspects of custom indoor network patch cables, from definition to advantages, applications, manufacturing process, and what to look for from cable manufacturers in the USA.
What Are Custom Indoor Network Patch Cables?
Network patch cables have connectors on both ends and transmit audio, video, , and data signals. There are two main types of patch cables: fiber optic patch cables and Ethernet cables.
Fiber optic network patch cables provide high-speed data connections between various equipment throughout a data center. They are used for long-distance transmissions for everything from Fiber to the Home to FTTx. Along the way are many data connections that need custom indoor patch cables that off-the-shelf cables can&#;t meet.
Ethernet network patch cables are used throughout data centers and home and office computer networks. They connect computers to network hubs, routers, and switches. The Ethernet cable types include Cat3, Cat5, Cat5E, Cat6, and Cat7.
See our complete listing of networking cables for further insight into Ethernet patch cables, fiber optic patch cables, custom composite cables, data cables, mil-spec cables, coax cables, and custom hybrid cables.
Advantages of Custom Indoor Network Patch Cables
The significant advantages of custom indoor network patch cable assemblies are that they can be pre-tested, manufactured in quantity, and dropped into place. Not only that, but compared to field installation, pre-terminated fiber optic cables can save money. Critical applications are fiber trunk cables in data centers, wire harnesses, and hybrid composite cables.
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Pre-terminated custom network patch cable assemblies are estimated to save half or more on installation costs. In addition, since the termination is precision polished and tested at the factory, these procedures are not needed in the field. That means there&#;s no need for field testing equipment or consumables, saving time and money.
That also allows faster installation and cable performance that&#;s already been measured. All that further reduces waste when cutting and trying cables and connectors in the field.
Optimizing USA Networks Networks: Fiber Trunk Cable Edge
Custom Indoor Network Patch Cable Applications
There are two main applications for indoor network patch cables.
. As the
5G global infrastructure
rapidly expands, custom copper network patch cables and fiber optic assemblies are needed in
small cell
networks to ensure seamless coverage throughout a city. There is a growing need for cables in data centers at the heart of the expanding cellular network.
. The
transportation world
is implementing
wireless networks
for Supply Chain 4.0 as they track shipments and reroute them as road conditions change or when a delivery destination changes at the last minute. That, too, requires custom network patch cables.
Custom Indoor Patch Cable Assembly Manufacturing Process
Buying and installing off-the-shelf network cables doesn&#;t require the same level of involvement as building a custom cable. Here&#;s an overview of the detailed process required to deliver high-quality custom cables.
. The design stage typically requires defining custom military cable requirements and the resulting performance criteria. Then, the designer creates the drawings and verifies that they meet the requirements. Once approved, the detailed specifications list and bill of materials are generated.
. The next stage is assembling a prototype. The resulting cable assembly will reveal any performance issues or parts sourcing problems and allow testing iterations of the custom cable assembly design. This results in finding the best assembly options.
. This step brings everything together: conductors, fiber optic cables, insulation, shielding, wrapping, shrink tubing, terminations, custom colors, artwork, logos, and product numbering.
. This stage involves
extensive product testing
that covers the broad areas of physical analysis (pull testing), environmental analysis (heat, cold, dust, moisture), signal integrity analysis, and insertion loss analysis.
. Sourcing suitable materials and components begins with design, is validated in prototyping, and is fulfilled in manufacturing. It&#;s all about providing a cost-effective military custom cable assembly and supporting that product throughout its life cycle.
What to Look for in a Custom Network Cable Manufacturer in the USA
Finding the right custom network cable assembly manufacturer is critical to your products. Going through the design, prototyping, production, and testing process to find that your product doesn&#;t work as required is not just a problem; it&#;s a disaster. Here are the essential elements for reviewing any cable manufacturer.
. Experience should be measured in decades; during that time, the manufacturer should relentlessly improve and advance their skills and product offerings.
. Prospective manufacturers should have extensive experience in your industry. Manufacturers with mil-spec experience should be the starting point. But they also need proven experience with all the requirements of your specific industry.
. The right custom cable assembly manufacturer must also have experience with your specific cable type. You don&#;t need to finance their education with your projects.
. You&#;re seeking a custom military cable assembly manufacturer because you don&#;t have the resources or expertise to do it yourself. Make sure the manufacturer you choose has those resources and expertise in abundance.
. Finding and buying the necessary components is crucial to manufacturing custom cable assemblies. Therefore, the chosen manufacturer should have extensive sourcing capabilities.
. Custom fiber optic cable assemblies require expertise backed by industry certification, recognition, and regulation compliance.
. The best custom cable assembly manufacturers engage you from your first moment of contact and through every step of every project. You can tell from the first call that they have your interests at heart.
It can be of further help to have a USA-based cable manufacturer. For further insight, see our article USA-Based Cable Manufacturing Helps Overcome Supply Chain Issues.
We Can Meet Your USA-Manufactured Network Cables Needs
If your requirements are already specified and ready for a quote for your current projects, we are prepared to meet your deadlines and pricing targets. Our extensive in-house services and advanced manufacturing capabilities are in place to meet your requirements.
But Cables-Unlimited offers much more than state-of-the-art manufacturing &#; our dedicated team is also known for going to great lengths to meet the needs of our customers, including working round-the-clock to meet tight turnaround time requirements.
Our sales representatives are standing by to assist you with product questions and quotes Monday &#; Friday, 8:00 am to 5:00 pm Eastern. Of course, you can also us or complete our contact form, and we&#;ll get right back to you.
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