Custom cable assemblies are a great way to bring your product designs to life. They allow you to create custom cable layouts that aren’t possible with standard cables. With them, you can build cable harnesses and other types of electronic enclosures that suit your specific needs. You can also use them as a means of customizing the look of your device or system. In this blog, we’ll explore what custom cable assemblies are, their benefits and some common applications.
What Are Custom Cable Assemblies?
Custom cable assemblies are special types of cables that are designed and manufactured to meet the specific requirements of a customer and application. This means that they are made to order and are not mass-produced like standard off-the-shelf cable assemblies.
Benefits of Custom Cable Assemblies
If you’re in the market for cable assemblies, you might be wondering why you should choose custom cable assemblies instead of pre-made cable kits. Here are five major benefits of using custom cable assemblies.
1. Reduced Waste, Cost & Time
Custom cable assemblies can reduce waste, cost and time. Using standard cables for your design may require you to use conductors, insulation and a connector. The connector may then require a crimp tool. With a custom cable assembly, you can choose the type of cable you want to use, resulting in less waste and cost. For example, if you’re designing a high-speed Ethernet cable, you don’t need as many conductors as you would for an HDMI cable. This can also be used to your advantage if you’re designing a custom cable that requires more conductors than those that are standard for your design.
2. Flexible Assembly
Cable assemblies that are made of flexible materials allow for easier routing and installation scenarios. Adaptable cable assemblies allow for routing through tight spaces. They can also be routed around obstructions such as when pulling cable through a window. If a cable is too thick or rigid to pass through a particular location, a flexible cable can be pushed through or routed over the top of the obstruction.
3. Improved Performance & Safety
Custom cable assemblies are designed to meet the specific needs of your application. This means that they can be optimized for performance, which can lead to improved efficiency and productivity. Custom cable assemblies can also improve safety in your application since they can be designed with features such as over-moulding or strain relief to help prevent accidental disconnection or electrical shocks.
4. Reduced Maintenance Costs
One way of reducing maintenance costs is to use custom cable assemblies. This is because they are designed for easy installation and replacement, and they can also be designed to be more resistant to damage from vibration or other factors. This can be important for applications where the cable assembly will be exposed to harsh conditions such as in outdoor or industrial applications.
Common Applications of Custom Cable Assemblies
Custom cable assemblies are a vital part of many industries such as healthcare, automotive, aerospace, and more. There are countless applications for custom cable assemblies. Here are 3 common examples:
1. Medical Devices
Custom cable assemblies are used in many medical devices, from MRI machines to heart monitors. They are essential for ensuring that these devices function properly and safely. MRI machines, for example, use extremely powerful magnets. This means that the cables used in these machines must be able to withstand high levels of electromagnetic force. Custom cable assemblies are designed to meet this challenge.
2. Automotive
The automotive industry relies heavily on custom cable assemblies. They are used in everything from brake systems to engine control systems. For instance, custom cable assemblies are used in engine control systems which need to be able to transmit large amounts of data quickly and accurately. This data includes everything from engine temperature to fuel levels.
3. Aerospace
Custom cable assemblies are widely used within the aerospace industry for things like aircraft and satellites. Many aircraft have custom cable assemblies because these cables can handle extreme weather conditions, high levels of vibration and temperature fluctuations.
Our heavy reliance on satellites means that they need to work efficiently and transmit large data not only quickly, but also accurately. This data includes everything from the satellite’s position to the condition of its solar panels, hence the important role of custom cable assemblies.
Should You Buy Custom Cable Assemblies?
Custom cable assemblies have become a popular choice for many industries. Unlike standard cable assemblies, custom cable assemblies are designed and built specifically for the customer, rather than being a standard product that’s been mass-produced. This helps companies to reduce wastage during the manufacturing process. These cables also offer flexibility during installation and give you better performance than standard cables.
Cornelius Electronics is a highly experienced and diversified manufacturer of cable assemblies and wiring harnesses for all types of industries. With over 40 years of experience in providing high-quality, custom cable assemblies and expertise in engineering, manufacturing, and quality control, Cornelius Electronics is able to provide its customers with products that meet their specific manufacturing requirements and exceed customer expectations.
