Is standard, off-the-shelf cable not meeting your needs? When you’re dealing with a complex application and standard cable seems to be falling short, custom cable assemblies might be the way to go.

As a cable technician, you know that purchasing the right cables are essential to any application requiring cable assemblies, whether it’s for setting up a home theater system that requires a special power cable, or an industrial application that needs a custom coax.

Poor wiring, or using standard cable just to make do, can lead to improper set up and technical issues. In the case of mission-critical applications for industrial use, a glitch can result in a temporary shutdown which can spell disaster.

Sure, standard cables may work in many instances, but custom cables come with their own set of advantages that off-the-shelf cables can simply not provide.

Let’s discuss the top 21 benefits and applications of custom cable assemblies that you should know.

Benefits of custom cable assemblies

Accuracy

Custom cables are manufactured as per the specifications in the design. This makes their application extremely precise to fit into the tolerance level detailed for the assembly.

Quantity

An exact amount of cables can be ordered tailored to the needs of the application. There is no wastage, nor are any excessive cables left after the assembly is completed. The exact count for conductor, size and stranding can be optimized during the design of the assembly.

Flexibility

The length of each cable can be manufactured exactly as per the requirement of the project. This makes the set up clean without any need to hide additional cables and wires.

Accountability

The person working with the custom cable assembly will have a closer association with the cable manufacturer. The manufacturer therefore is accountable for the quality and standard of the cables that have been ordered, as well as ensures that the set up is functional as desired.

Material Requirement

Materials used for construction of the cable such as shield, insulation, jacketing material can all be specified to suit the application. Control on the material sources and manufacturing process can also be detailed in case of critical applications such as the medical industry.

Quality Assurance

Applicable test data such as electrical parameters, tolerances, temperature performance and resistance to chemical exposure can all be supplied by the custom cable manufacturer to ensure that the cable is tested for the given parameters before assembly.

Saves Time

Custom cables save many hours which would have otherwise been spent struggling with making standard cables fit the needs of the application. Hurdles like cable length, connector ends, resistance of cables, faulty cables and mismatch of specification can all be eliminated by just ordering custom cables.

Higher Performance

Due to the fact that custom cables undergo a stringent manufacturing process and are extensively tested, they may offer higher performance as compared to their standard, bulk or store ordered counterparts. With a longer lasting life span, custom cables save money in the long run.

Multiple Functions

For specialized applications such as security and surveillance, custom cables can be manufactured to incorporate multiple functions such as power, signal, optical fiber, coax, video, cable shielding and more, all into one cable. This specialized solution takes us minimal space and is built for unmatched performance.

Additional Services

Many a times custom cable manufacturers offer additional services such as laser marking and even design support for choosing the best custom cables for your application, which could serve as a big cost saving factor.

Professional Branding

Specifications for aesthetics such as color matching, look and feel, as well as texture of the cable can be detailed to the cable manufacturer when you order your custom cable. You can even add labels for easy identification. This gives a clean, neat and tidy finish to the project making it look like the hard work of a professional.

Applications of custom cable assemblies

Medical Industries

Healthcare operations and hospitals have very detailed requirements for cables and wiring. Conditions such as high temperatures or large amount of moisture used for sterilization of medical instruments, make the cables deteriorate and disintegrate at a much faster rate. Thus, the medical industry needs custom cables that are able to sustain this repeated exposure day in and day out.

Telecommunications

Custom cables are manufactured for the digital age and broadcasting using fiber optic technology. Whether we are using our Smartphone, laptop, computer, tablet or anything that requires a network these cables help in the quick transfer of data. For cable technicians, custom fiber optic cables are excellent for meeting critical network needs when standard patch cables can’t do the job.

Military

From powering overseas military bases to securing confidential communication, to the units on the field, the military uses custom cabling and wiring for many of its branches. Also, cables used in military operations, need to endure harsh environmental conditions and perform under intense exposure, especially when on missions, so custom cables are a good choice to meet these critical requirements.

Aerospace

With the advancement of technology there is a continuous increase in the list of products needed by the aerospace industry. All digital instruments and workspaces need to have quality cables for optimum performance of any aircraft. From the hard wiring in the cockpits to the receiving units at the base, precision cables are integral to the success of the flight.

Automotive

The automotive industry is one of the largest industries that requires mass usage of cable assembly services. Proper cable assembly from the dashboard to the engine are critical for the efficient working of any vehicle.

Electronics

There’s much more that goes into electronic gadgets than just their look and style. Behind the user interface a lot of custom cables are at work to ensure that the product functions well and delivers what it’s meant to do, while at the same time being compact and user-friendly.

Utility Industry

Public utility companies serve many functions from powering homes to streetlight timings and other applications, all of which need custom cables to transmit power.

Industrial Controls

Massive machinery and hydraulics that are needed in any production line, require cables not just to transmit power but signals as well.

Sensors and Scanners

Custom cables are used widely in different devices and equipment which could be point-of-sale(POS) scanners, terminals of instruments, and automated kiosks.

Testing and Measuring Equipment

Testing and measuring devices, used in continuity testing for example, are critical in verifying whether a particular equipment, model, gadget or appliance meets required specifications.  These instruments might need simple wiring all the way to complex custom assemblies for high quality and precise testing results.

Where to Buy

Since custom cable assembly specifications vary across different industries and applications, a trusted custom cable provider can offer ready stocked custom cables in popular cable types and lengths for high in-demand applications.

For detailed specifications that meet your unique needs, you can design your own custom cable by choosing your cable type, cable brand, connector types and more, that results in a cable that’s perfect for your application.

At PacRad, we specialize in providing custom cable assemblies that fit the specifications and needs of any assembly. Our cables are quality tested for performance. If you are ready with a preliminary design or even if you need help with cable assembly design we can be of assistance. If you are looking for custom cables to be delivered fast, easily and at a competitive price – let’s talk!