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?

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?

Superior Performance

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.

Quality Assurance

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.

Increased Efficiency

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.

Saves Time and Money

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.

Raise Brand Awareness

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.

Applications of Custom Cable Assemblies

Custom cable assemblies are used in various applications, each with its specifications, regulations, and requirements.

Aerospace

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 & Defense

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

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.

Telecommunications

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.

Industrial

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.

Automotive

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 1977, we have been a leading cable supplier and distributor in North America, providing competitive pricing and excellent customer service.

Contact us at 905-624-5241 today to find out how we can help you find the right custom cable assembly for your application!